Vacuum Feedthroughs for High-Integrity Sealed Systems

Posted by admin on

Why Vacuum Feedthroughs Are Essential

Vacuum feedthroughs allow electrical, optical, fluid, or mechanical transfer into or out of a sealed vacuum chamber without compromising the chamber’s integrity. They are crucial in semiconductor processing equipment, scientific research instruments, aerospace simulation chambers, and industrial high-temperature vacuum furnaces. Even the slightest leak can affect process quality, research accuracy, or equipment performance—making hermetic sealing absolutely essential.

Design Requirements for High-Vacuum Environments

Vacuum feedthroughs require materials that tolerate thermal expansion, pressure gradients, plasma exposure, outgassing, and radiation. Complete Hermetics engineers each feedthrough using precision glass-to-metal or ceramic-to-metal bonds calibrated to maintain ultra-low leak rates under severe operating conditions. These feedthroughs maintain performance from cryogenic to extreme high-temperature environments.

Configurations & Materials

Vacuum, electric, glass, and ceramic feedthroughs—often used interchangeably—serve the same core purpose: to route electrical current into or out of a hermetic or vacuum system while preventing any gas leakage. Complete Hermetics designs and manufactures custom glass-to-metal and ceramic-to-metal feedthroughs, including multi-pin and bulkhead hermetic feedthroughs that provide multiple electrical paths through a single flange. Available in laser-weld or solder-in styles, these feedthroughs deliver reliable performance in harsh environments. They are widely used in submersible pumps, downhole drilling tools, exploration instruments, implantable medical devices, and cryogenic surgical probes, where stable electrical continuity and long-term hermeticity are mission-critical.

Applications in High-Tech Sectors

Vacuum feedthroughs support:

  • Plasma etching & PVD/CVD semiconductor tools
  • Space environment simulation chambers
  • Ion beam accelerators & laboratory research equipment
  • Industrial furnaces & metallurgical processing
  • Aerospace test stands requiring high vacuum integrity

Testing & Verification

Every feedthrough undergoes low-helium-leak testing, electrical resistance measurement, thermal cycling, and long-duration vacuum compatibility validation. These processes guarantee reliability in systems where contamination or pressure loss cannot be tolerated.

Contact Complete Hermetics Today for Your Hermetic Solutions

Complete Hermetics provides high-performance vacuum feedthroughs and hermetic sealing technologies. From glass-to-metal or ceramic-to-metal configurations, each feedthrough is engineered with exacting precision to meet your application requirements.

Semiconductor Hermetic Packages for Precision Microelectronics

Posted by admin on

Hermetic Packages Engineered for Demanding Environments

Complete Hermetics manufactures a full range of hermetic microwave, hybrid, power, photonic, and telecom packages designed for high-reliability applications in defense, aerospace, energy, medical, and advanced electronics industries. These hermetically sealed microelectronic enclosures are used in mission-critical environments where extreme temperature, vibration, pressure differentials, radiation, and chemical exposure can compromise sensitive semiconductor devices. Each package is engineered to protect internal circuitry, maintain signal integrity, and ensure decades of stable performance in harsh operating conditions.

Microwave and Hybrid Hermetic Packages

For RF, microwave, and millimeter-wave systems, Complete Hermetics produces precision hermetic microwave and hybrid packages compliant with MIL-883, MIL-PRF-38354, and JEDEC-9C standards. These packages incorporate customized feedthrough diameter combinations to meet complex impedance requirements, ensuring high-frequency stability and low-loss performance. Typical constructions include glass-to-metal seals, ceramic-to-metal seals, bent leads, and GPO connectors. Housing materials such as Kovar, stainless steels, CRS, Alloy 52/46, titanium, and aluminum provide controlled thermal expansion, structural robustness, and high-temperature endurance. Every unit undergoes stringent inspection including helium leak testing to ≤ ATM 1×10-8 cc/sec He, insulation resistance tests, and pin-pull tests to verify mechanical integrity.

High-Power Hermetic Packages for Thermal Demands

Complete Hermetics also manufactures hermetic power packages engineered to support high electrical loads and significant thermal dissipation. Many of these power enclosures utilize copper tungsten, copper molybdenum, and copper heat-spreading materials that effectively manage thermal expansion while allowing the enclosure to dissipate heat efficiently. These packages often incorporate glass feedthroughs, ceramic feedthroughs, and DIL/DIP packages with hermetic glass seals to ensure reliable electrical performance under high voltage and high current. Built to MIL-883/MIL-PRF-38354 specifications, each power package is tested for hermeticity, insulation resistance, pin strength, and dimensional accuracy to guarantee long-term durability in energy systems, aerospace modules, and industrial power equipment.

Photonic, Fiber-Optic, Telecom & Biomedical Hermetic Packages

For optical, telecom, and biomedical applications, Complete Hermetics produces hermetically sealed enclosures used in fiber-optic systems, photonic communication devices, biomedical diagnostics, and high-speed signal modules. These packages are built using durable materials including Kovar, stainless steels, CRS, Alloy 52/46, titanium, and aluminum, offering excellent thermal stability and corrosion resistance. Typical constructions include High-Temperature Co-Fired Ceramics (HTCC), multi-layer ceramic feedthroughs, glass-to-metal seals, and GPO or window-lens packages supporting optical coupling and high-frequency performance. With hermeticity levels of ≤ ATM 1×10-8 cc/sec He, these enclosures maintain optical clarity, electrical isolation, and mechanical precision even in harsh or sterilized environments. Complete Hermetics supports custom prototype development through full mass-production, ensuring tailored solutions for next-generation fiber-optic networks, photonic sensors, and biomedical instrumentation.

Commitment to Engineering Excellence

Across all package types—microwave, hybrid, power, photonic, telecom, and biomedical—Complete Hermetics engineering team works directly with customers to optimize design, material selection, sealing technologies, and testing protocols. Every hermetic package is built with strict process control and complete traceability, ensuring unmatched precision and customer satisfaction for high-performance semiconductor assemblies.

Contact Complete Hermetics:

Choose Complete Hermetics for ultra-reliable semiconductor hermetic packages and other advanced hermetic products engineered for advanced electronic systems.

Titanium headers

Battery End Seals for High-Reliability Power Systems

Posted by admin on

Why Battery End Seals Are Critical

Battery end seals ensure airtight, long-term protection in lithium, silver-zinc, and other high-performance battery chemistries. These seals prevent electrolyte leakage, moisture intrusion, internal corrosion, and pressure imbalance—issues that can shorten battery lifespan or cause critical device failures. In aerospace, medical implants, defense equipment, and industrial monitoring systems, battery reliability directly affects user safety and equipment performance. As batteries become smaller and more energy-dense, the importance of robust hermetic sealing continues to increase.

Advanced Glass-to-Metal Technologies for Modern Batteries

Complete Hermetics manufactures glass-to-metal sealed lids and battery end caps designed for high pressure, extreme temperatures, and high-current cycling. Glass-to-metal seals provide strong chemical resistance, electrical insulation, and long-term bonding strength. By pairing controlled-expansion alloys such as Kovar or stainless steel with high-reliability glass, Complete Hermetics ensures a leak-proof interface capable of withstanding decades of use.

Applications Across Mission-Critical Industries

Battery end seals are used in:

  • Implantable medical devices (pacemakers, neurostimulators)
  • Aerospace telemetry and communication modules
  • Military-grade energy storage
  • Extreme-environment sensors & monitoring systems
  • Backup power modules for critical infrastructure

These seals ensure stable electrical output even in the presence of shock, vibration, and rapid thermal cycling.

High-Reliability Testing & Validation

Each battery seal undergoes helium leak testing, electrolyte exposure resistance, temperature cycling, and mechanical stress evaluation. Plating options—such as nickel, gold, or tin—enhance solderability, conductivity, and corrosion protection for long-term reliability.

Contact Complete Hermetics Today

Complete Hermetics delivers safe, durable, and long-lasting battery end seals engineered for high-performance applications. The team also produces advanced battery feedthroughs, glass-to-metal lids, and other reliable custom hermetic products built to withstand demanding environments. With precision manufacturing and proven sealing technologies, every component ensures consistent, long-term reliability.

Advanced Ceramic-to-Metal Seals and Feedthroughs for High-Temperature Performance

Posted by admin on

Why Ceramic-to-Metal Seals Are Superior

Ceramic-to-metal seals provide unmatched insulation strength, temperature resistance, and structural durability—making them ideal for systems exposed to extreme conditions. Unlike glass seals, ceramics retain mechanical and electrical stability at temperatures exceeding 500°C and remain intact during rapid thermal cycling. These properties make CTM seals indispensable in aerospace propulsion, medical imaging equipment, semiconductor fabrication tools, and scientific instrumentation.

Material Properties & Bonding Precision

Complete Hermetics uses high-purity alumina ceramics, metalized with tungsten-molybdenum or moly-manganese layers, to enable strong brazed joints with Kovar, titanium, or stainless steel housings. This combination allows ceramic-to-metal seals to achieve extremely low leak rates and high dielectric breakdown voltage. Optional plating—gold, nickel, or silver—improves conductivity, corrosion resistance, and long-term material stability.

Applications Across High-Temperature Industries

Ceramic-to-metal seals are essential in:

  • High-voltage power systems
  • Vacuum and plasma processing equipment
  • RF amplifiers and radar transmitters
  • Aerospace ignition and propulsion assemblies
  • Nuclear diagnostic sensors
  • Industrial heating and furnace control systems

Engineering Collaboration & Testing

Complete Hermetics works closely with engineers to determine ceramic thickness, dielectric spacing, pin configurations, and mounting styles tailored to each application. Every component undergoes helium leak detection, thermal shock testing, vacuum cycling, and electrical qualification to ensure longevity and reliability.

Contact Complete Hermetics

Count on Complete Hermetics for robust, precision-engineered ceramic-to-metal seals and feedthroughs— your trusted partner for extreme-environment reliability.

Hermetically Sealed Packages for Harsh-Environment Electronics

Posted by admin on

Purpose of Hermetic Packages

Hermetically sealed packages protect sensitive microelectronics against moisture, contaminants, chemical vapor, radiation, vacuum conditions, and extreme temperature cycles. Without hermetic protection, microchips, sensors, and laser components can suffer from corrosion, outgassing, electrical drift, or catastrophic failure. In aerospace, defense, semiconductor, and medical applications, hermetic packaging ensures long-term performance—even in environments where failure is not an option.

Types of Hermetic Packages Offered

Complete Hermetics manufactures hermetic microwave and hybrid packages for defense, aerospace, energy, and medical applications, delivering rugged microelectronic enclosures engineered for harsh environments where reliability is critical.

Complete Hermetics produces high-reliability hermetic power packages using copper tungsten, copper molybdenum, and copper materials to support high thermal expansion, efficient heat dissipation, and long-term hermetic performance through glass-to-metal or ceramic-to-metal seals.

Complete Hermetics manufactures hermetic packages for photonic, fiber-optic, telecom, and biomedical systems, enabling stable high-speed optical performance and providing fully customized solutions from prototype to production.

Precision Sealing & Manufacturing Process

Hermetic packages are sealed using laser welding, seam sealing, brazing, or glass-to-metal sealing depending on mechanical, thermal, and electrical requirements. Complete Hermetics ensures proper metallization, plating, internal routing, and thermal expansion matching to guarantee structural and environmental reliability. Internal cavities can be customized for chip alignment, lens coupling, fiber-optic feedthroughs, or high-speed signal pathways.

Applications in Demanding Industries

These packages are used in:

  • Satellites and deep-space communications
  • Radar & military electronics
  • Medical diagnostic technology
  • Semiconductor laser drivers
  • Harsh-environment sensor modules
  • High-reliability communication systems

Contact Complete Hermetics:

Choose Complete Hermetics for high-performance hermetically sealed packages engineered for extreme reliability and precision.

Medical Hermetic Seals for Life-Critical Electronic Devices

Posted by admin on

Why Hermetic Seals Are Essential

Medical hermetic seals play a critical role in ensuring the safety, reliability, and biocompatibility of implantable and diagnostic electronics. When devices operate inside the human body or are exposed to sterilization processes, they must withstand moisture, bodily fluids, chemical exposure, and extreme thermal variations. Even the smallest leak can cause internal corrosion, signal failure, or biological contamination. As modern medical devices become smaller yet more capable, the demand for advanced hermetic sealing technologies grows significantly.

Glass-to-Metal & Ceramic-to-Metal Sealing Technologies

Complete Hermetics designs medical-grade seals using glass-to-metal (GTM) and ceramic-to-metal (CTM) sealing methods. Glass seals provide cost-effective, high-strength bonding between metal housings and conductive pins, while ceramic seals are ideal for high-voltage or long-term implants due to their exceptional dielectric strength. Using materials such as titanium, stainless steel, and high-purity alumina ceramics, these seals are engineered to perform reliably in demanding biological environments.

Regulatory-Ready Testing & Biological Safety

Medical hermetic seals must meet FDA, ISO 14708, IEC 60601, and biocompatibility standards. Complete Hermetics performs rigorous testing—including helium leak detection, sterilization simulation, thermal shock, electrical insulation analysis, and X-ray inspection—to ensure every seal meets life-critical reliability requirements. Traceability, cleanliness, and manufacturing consistency are maintained at every step.

Applications in Modern Healthcare

Medical hermetic seals enable secure operation in:

  • Pacemakers & implantable cardioverter defibrillators (ICDs)
  • Neurostimulation & pain-management implants
  • Implantable batteries & power modules
  • Surgical navigation tools
  • Diagnostic imaging equipment
  • Long-term biosensor implants

Contact Complete Hermetics

For precision-engineered medical hermetic seals that support life-critical technology, trust the expertise of Complete Hermetics.

Hermetic Bulkhead Feedthroughs for Secure System Penetrations

Posted by admin on

What Are Bulkhead Feedthroughs?

Hermetic bulkhead feedthroughs are specialized sealing components that permit electrical conductors to pass through pressure boundaries while maintaining an absolute airtight separation between two environments. These components are essential for systems where internal integrity must not be compromised—such as vacuum chambers, propulsion systems, laboratory reactors, marine equipment, and industrial process vessels.

How Bulkhead Feedthroughs Maintain Integrity

Bulkhead feedthroughs must withstand intense mechanical stress, extreme temperatures, pressure cycling, chemicals, radiation, and vibration. Complete Hermetics engineers these feedthroughs using robust glass-to-metal and ceramic-to-metal sealing technologies that ensure leak rates as low as 1×10-8 cc/sec. These seals resist cracking, corrosion, and long-term fatigue.

Configuration & Mounting Options

Vacuum, electric, glass, and ceramic feedthroughs—terms often used interchangeably—serve the essential function of carrying electrical current into or out of a hermetic or vacuum system while maintaining an airtight seal. Complete Hermetics designs and manufactures custom glass-to-metal and ceramic-to-metal feedthroughs engineered to prevent gas transmission through pressure barriers.

The company also produces multi-pin hermetic feedthroughs and bulkhead electrical feedthroughs, which route multiple electrical paths through a single flange-mounted bulkhead. Available in laser-weld or solder-in configurations, these feedthroughs are built for extreme environments. They are used in submersible pumps, downhole drilling tools, exploration devices, implantable medical systems, and cryogenic surgical probes, where long-term electrical continuity and hermetic integrity are essential.

Industry Applications

Bulkhead feedthroughs are widely used in:

  • Aerospace propulsion and environmental testing
  • Subsea robotics & marine exploration vessels
  • Cleanroom vacuum chambers & semiconductor tools
  • High-pressure reactors and cryogenic systems
  • Defense-grade electronics and hardened enclosures

Material Strength & Long-Term Reliability

Using premium alloys such as titanium, Inconel, Kovar, and stainless steel, Complete Hermetics ensures mechanical stability under prolonged operational stress. Ceramic insulators and precision plating improve voltage tolerance and corrosion resistance.

Contact Complete Hermetics

For durable, precision-engineered hermetic bulkhead feedthroughs, trust the proven expertise of Complete Hermetics.

Contact Form: https://www.completehermetics.com/contact-us/ | Phone: 714-265-1238 | Email: info@completehermetics.com

MIL-SPEC Hermetic Connectors

Custom Hermetic Connectors for Extreme Environments

Posted by admin on

Why Custom Hermetic Connectors Are Needed

Custom hermetic connectors offer airtight electrical interface solutions for systems operating under vibration, shock, extreme temperatures, pressure differentials, or chemical exposure. When standard connectors cannot meet the demands of aerospace vehicles, medical implants, industrial machinery, or defense platforms, custom hermetic connectors provide the durability, stability, and leak-proof performance required for uninterrupted operation.

Glass-to-Metal and Ceramic-to-Metal Sealed Connectors

Complete Hermetics produces connectors utilizing both glass-to-metal (GTM) and ceramic-to-metal (CTM) sealing technologies. GTM connectors offer excellent cost efficiency and strong bonding, while CTM connectors provide exceptional dielectric strength, temperature tolerance, and long-term structural integrity. The sealing method chosen depends on the required voltage, frequency, biological exposure, and operational environment.

Custom Styles, Geometries & Materials

Customers can specify circular, rectangular, bulkhead, inline, high-voltage, RF, or multi-contact connector designs. Materials like Kovar, stainless steel, aluminum, and titanium enable optimal performance across aerospace, medical, and industrial environments. Plating options—gold, nickel, or tin—improve conductivity, solderability, and corrosion resistance.

Industry Applications

Custom hermetic connectors are vital in:

  • Deep-space avionics and propulsion control
  • Implantable medical devices and surgical robotics
  • Harsh-environment test systems
  • High-temperature turbine monitoring
  • Subsea digital communication systems
  • Military-grade power modules & sensors

Engineering Support & Performance Verification

Each connector undergoes rigorous testing including helium leak detection, thermal cycling, high-voltage dielectric testing, vibration testing, insulation resistance, and mechanical durability assessment. Complete Hermetics collaborates with engineers to ensure every custom connector meets mechanical, electrical, and environmental requirements.

Contact Complete Hermetics

Choose Complete Hermetics for precision-built, fully customizable hermetic connectors engineered to exceed performance expectations.

Hermetic Feedthroughs for High-Reliability Sealing

Posted by admin on

What Are Hermetic Feedthroughs?

Hermetic feedthroughs are essential components that allow electrical signals, power, or data to pass through sealed enclosures without allowing any external elements—such as gas, fluid, vapor, or contaminants—to enter. These components are vital in aerospace avionics, semiconductor fabrication, medical implants, power systems, defense platforms, and industrial vacuum equipment. When systems are exposed to high pressure, vacuum, radiation, corrosive chemicals, or temperature fluctuations, hermetic feedthroughs act as the primary barrier protecting internal electronics and maintaining long-term operational stability.

How Hermetic Feedthroughs Maintain Airtight Integrity

A high-performance hermetic feedthrough is created through glass-to-metal or ceramic-to-metal sealing, a process in which insulating materials bond molecularly with the metal shell and internal pins. By carefully matching the coefficient of thermal expansion between materials, Complete Hermetics ensures the seal remains tight even under vibration, pressure cycling, and thermal shock. This engineering precision prevents micro-cracks, corrosion pathways, and seal degradation—factors that can cause catastrophic system failure.

Advanced Materials for Maximum Performance

Hermetic feedthroughs are constructed using specialized alloys such as Kovar, stainless steel, Inconel, and titanium, each chosen for its thermal stability and mechanical resilience. High-purity ceramics offer exceptional dielectric strength, while plating finishes—gold, silver, or nickel—enhance conductivity and corrosion resistance. These materials allow feedthroughs to survive extremely harsh operating environments, from deep-space vacuum to high-pressure oceanic applications.

Applications Across Industries

Hermetic feedthroughs are indispensable in:

  • Satellite propulsion and orbital control systems
  • Semiconductor vacuum etching and deposition chambers
  • Medical imaging, diagnostics, and implantable electronics
  • High-temperature industrial furnaces
  • Defense communication & targeting systems
  • Cryogenic and high-voltage environments

Custom Engineering Expertise

Every environment demands unique electrical, mechanical, and thermal characteristics. Complete Hermetics provides fully customized feedthrough solutions—with tailored pin counts, geometries, voltage ratings, sealing materials, and mounting styles. Engineers collaborate with customers throughout design, prototyping, and qualification to ensure maximum performance.

Contact Complete Hermetics:

For high-performance hermetic feedthroughs engineered for mission-critical applications, partner with Complete Hermetics—your trusted leader in precision hermetic sealing.

Hermetic Seals and Feedthroughs for Extreme Environments

Posted by admin on

Why Hermetic Seals Are Essential

Hermetic seals are critical to protecting sensitive electronics from gas, liquid, and pressure infiltration. Whether in aerospace flight control systems, industrial power assemblies, or medical equipment, the success of an electronic device often depends on the integrity of its hermetic sealing. When systems operate under high stress or environmental fluctuation, a small leak can lead to catastrophic failure.

Complete Hermetics Expertise

Complete Hermetics is a trusted hermetic seal manufacturer with decades of engineering experience. The company designs and fabricates both glass-to-metal and ceramic-to-metal feedthroughs, each tailored to meet precise mechanical, thermal, and electrical requirements. Every product undergoes helium leak detection, electrical insulation testing, and dimensional verification to ensure it exceeds global reliability standards. Their multidisciplinary team collaborates closely with clients to optimize performance, durability, and manufacturability for each application. With a commitment to innovation, Complete Hermetics continues to advance sealing technologies that meet the evolving needs of aerospace, medical, and defense industries.

Glass-to-Metal Seals and Applications

A glass-to-metal seal is formed when molten glass bonds tightly to metal under carefully controlled thermal expansion. The resulting structure creates a gas-tight joint ideal for devices exposed to temperature swings or humidity changes. Common applications include aviation sensors, industrial pumps, high-voltage connectors, and sealed relays. Compression and matched seals are both available depending on the intended use environment.

Ceramic-to-Metal Alternatives

When systems demand higher operating voltages or extreme temperature resistance, ceramic-to-metal seals provide superior dielectric strength and corrosion resistance. Complete Hermetics engineers these seals for medical scanners, power distribution modules, and vacuum enclosures used in aerospace and research.

Customization and Finishing Options

Materials such as stainless steel, Inconel, Kovar, and titanium are combined with custom plating—gold, nickel, or silver—for enhanced conductivity and solderability. Each configuration is designed in collaboration with the customer to meet functional, thermal, and geometric requirements.

Contact Complete Hermetics

For precision-engineered hermetic seals and feedthroughs that perform in the harshest conditions, trust Complete Hermetics —your global partner in dependable sealing solutions.

Contact Info: