Titanium headers

Why Are Battery End Seals Important?

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The Role of Hermetic Sealing in Battery Technology

In advanced battery systems, particularly lithium battery seals, the quality and precision of battery end seals are critical to performance and longevity. These seals serve as the frontline defense against environmental stressors such as temperature fluctuations, moisture, and electrochemical reactions. Without proper sealing, battery systems are at risk of failure, leading to reduced efficiency, safety hazards, and shortened service life.

Designed to Withstand Harsh Environments

Complete Hermetics specializes in hermetic products engineered for extreme conditions. Their custom glass-to-metal sealing technology provides exceptional resistance to corrosive agents, pressure changes, and electrical stress. Designed to perform from -40°C to over +150°C, these battery end feedthrough seals are essential for industries where reliability is non-negotiable—medical devices, communication infrastructure, weaponry, and automotive systems, to name a few.

Precision Materials and Rigorous Testing

Complete Hermetics offers tailored solutions using robust materials such as stainless steel, titanium, and alloy 52 for both the housing and internal pins. High-performance glass materials like Corning 9010 and TA23 are used to ensure superior sealing integrity. Each unit undergoes a 100% leak test with a sensitivity as low as 1×10⁻⁸ cc He/sec. Additional tests for electrical isolation and breakdown voltage are available upon request to guarantee optimal performance in demanding applications.

Partner with Complete Hermetics for Reliable Battery Seals

If your application depends on durable and high-performance battery end feedthrough seals, look no further than Complete Hermetics. With decades of experience in lithium battery seals and custom hermetic solutions, their team ensures precision engineering, rigorous testing, and fast turnaround times. Whether you’re building next-generation medical devices or mission-critical defense systems, Complete Hermetics delivers the reliability your innovations demand.

Contact Complete Hermetics today to discuss your battery sealing requirements and explore how their expertise in hermetic products can support your next breakthrough.

MIL-SPEC Hermetic Connectors

Everything You Need to Know About Hermetic Connectors: Top 20 Frequently Asked Questions

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Hermetic Connectors: Top 20 Frequently Asked Questions

Hermetic connectors are vital components in high-performance applications where airtight, moisture-resistant, and pressure-proof connections are critical. Whether you’re in aerospace, defense, medical, or industrial manufacturing, understanding these connectors can help you make better design decisions.

Here are the most frequently asked questions about hermetic connectors—answered clearly and concisely.

1. What is a hermetic connector?

A hermetic connector is an electrical connector that features a hermetically sealed interface to prevent the ingress of gases, liquids, and contaminants.

2. How do hermetic connectors work?

They work by using airtight materials—often glass-to-metal or ceramic-to-metal seals—that prevent any leakage across the barrier, maintaining the integrity of the system.

3. What is the difference between hermetic and non-hermetic connectors?

Non-hermetic connectors do not offer gas or moisture sealing, making hermetic connectors the go-to choice for critical, sealed environments.

4. What materials are used in hermetic connectors?

Typical materials include stainless steel, Inconel®, Kovar®, ceramics, and borosilicate glass for their thermal and chemical stability.

5. Are hermetic connectors waterproof or airtight?

Yes, they are designed to be both airtight and moisture-proof, ideal for high-pressure and vacuum environments.

6. What are hermetic connectors used for?

They are commonly used in aerospace, military, medical devices, oil & gas, vacuum chambers, and space technology.

7. Where are hermetic connectors commonly installed?

Applications include sensors, battery systems, vacuum systems, implantable devices, and satellite components.

8. How do you test a hermetic seal on a connector?

Common tests include helium leak detection and pressure testing to ensure airtight performance.

9. What are the temperature and pressure ratings for hermetic connectors?

Many hermetic connectors operate from -65°C to +200°C and withstand high pressures, depending on the design and materials used.

10. Can hermetic connectors be used in high-vacuum environments?

Yes, they are ideal for vacuum chambers, particle accelerators, and space applications due to their gas-tight sealing.

11. What industries use hermetic connectors?

Industries include:

  • Aerospace & Defense
  • Medical & Biomedical
  • Energy (Nuclear & Oil)
  • Industrial Automation
  • Telecommunications

12. Can I get custom hermetic connectors for my application?

Yes, many manufacturers such as Complete Hermetics offer custom hermetic connector solutions tailored to your voltage, current, pressure, and mounting needs.

13. What certifications are required for hermetic connectors in aerospace or medical devices?

MIL-SPEC (e.g., MIL-DTL-38999), ISO 9001, and other industry-specific certifications are often required for regulated environments.

14. What are MIL-SPEC hermetic connectors?

These are hermetic connectors designed and tested to meet U.S. military standards for reliability and performance.

15. Are there hermetic connectors for fiber optics or coaxial cables?

Yes, hermetic feedthroughs are available for fiber optics, RF, and coaxial connections.

16. What is a glass-to-metal hermetic seal?

A glass-to-metal seal uses glass fused to metal at high temperatures to create an airtight, corrosion-resistant seal.

17. What is a ceramic-to-metal seal in hermetic connectors?

Ceramic-to-metal seals are used when higher dielectric strength or temperature resistance is needed.

18. How do I choose the right hermetic connector for my project?

Consider:

  • Electrical specs
  • Environment (temperature, pressure)
  • Mounting configuration
  • Sealing method
  • Material compatibility

19. Can hermetic connectors be reused?

Some are reusable if undamaged, but many applications—especially in aerospace or medical—require new connectors for each use.

20. What are TO headers and how are they related to hermetic connectors?

TO (Transistor Outline) headers are hermetically sealed components used in packaging semiconductors and sensors—often integrated with hermetic connectors.

✅ Need Hermetic Connector Solutions You Can Trust?

Contact Complete Hermetics today to learn more about our custom hermetically-sealed connectors, circular hermetic connectors, rectangular hermetic connectors, and MIL-Spec hermetic connectors. We offer a wide range of standardized sizes and can tailor our designs to meet your most demanding requirements.

Vacuum Viewports

Best Custom Vacuum Viewports for Precision Optical Applications

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In industries where performance under extreme vacuum and temperature conditions is non-negotiable, vacuum windows—also known as hermetic windows, high vacuum viewports, or hermetically sealed viewports—are essential components. These specialized hermetic products serve as transparent barriers that maintain airtight seals while allowing optical, laser, or infrared transmission in vacuum systems.

Engineered for High Vacuum Precision

Custom vacuum viewports play a critical role in maintaining system integrity in high-stakes applications such as defense optics, space instrumentation, medical endoscopy, and laser designation. These components must meet demanding specifications for both optical clarity and hermetic sealing. Complete Hermetics stands at the forefront of this technology, offering precision-engineered high vacuum viewports that are manufactured to meet or exceed MIL-PRF-13830 standards.

Advanced Materials and Construction

To deliver reliability across harsh environments, Complete Hermetics provides hermetic windows in a variety of customizable materials:

  • Window Options: Sapphire, Fused Silica, Glass, Magnesium Fluoride, Zinc Selenide
  • Flange Materials: Stainless Steel (CF, NW), Kovar, Titanium, Aluminum

These materials are selected based on application-specific requirements such as thermal expansion, optical transmission range, and chemical resistance. All assemblies are leak-tested to a stringent <1×10⁻⁹ Atm·cc/sec HE rate and operate across an impressive thermal range from -100°C to 450°C.

Tailored to Your Specifications

From aerospace-grade sapphire windows to magnesium fluoride lenses for UV systems, each hermetically sealed viewport is custom-built in nearly any shape or size to integrate seamlessly with your platform. Whether you require circular, rectangular, or complex geometry, Complete Hermetics delivers solutions that ensure maximum performance and longevity.

Partner with Complete Hermetics

When precision matters most, trust Complete Hermetics for your custom vacuum viewports and hermetic product needs. Contact us today to discuss your application and experience the unmatched quality of our vacuum windows, laser-grade optics, and hermetically sealed viewports engineered to perform under pressure.

MIL-SPEC Hermetic Connectors

Hermetic Connectors for Rugged Environments: Precision You Can Rely On

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In demanding industries where absolute reliability is essential, hermetic connectors are a cornerstone of secure and stable interconnect technology. Engineered to perform under extreme pressures, high temperatures, and harsh environmental conditions, these hermetic products ensure the integrity of electronic systems by preventing the ingress of gases or moisture. Whether for aerospace, defense, or industrial use, custom hermetic circular connectors play a pivotal role in mission-critical applications.

Precision Engineering with Custom Hermetic Circular Connectors

Complete Hermetics specializes in manufacturing both glass-to-metal and ceramic-to-metal sealed connectors, delivering unmatched durability and performance. The company produces custom hermetic circular connectors using traditional materials like Stainless Steel and Kovar, along with lightweight alternatives such as Aluminum and Titanium. These materials are ideal for applications requiring reduced weight without sacrificing strength or seal integrity. Their circle hermetic connectors are available for solder-in and laser weld installations, providing flexibility across a range of engineering requirements.

Durability with Hermetic Rectangular Connectors

In addition to circular models, Complete Hermetics manufactures rectangular hermetic connectors designed for robust defense and industrial environments. These Sub D and other hermetically sealed rectangular formats meet the highest standards of durability and are engineered to withstand rugged operational settings. Like their circular counterparts, these are available for both solder and laser weld options, ensuring seamless integration into existing systems.

MIL-Spec Hermetic Connectors for Aerospace and Defense

The company’s most advanced offerings include MIL-Spec hermetic connectors, such as the highly trusted MIL-DTL-38999 circular connectors. These are a preferred solution for aerospace and military applications, offering nine shell sizes, multiple coupling methods, and a variety of contact arrangements. Complete Hermetics’ 38999 models meet full compliance with MIL-DTL-38999 standards, ensuring optimal performance in the field.

Partner with Complete Hermetics for High-Reliability Hermetic Solutions

When it comes to precision, durability, and absolute hermetic sealing, Complete Hermetics delivers superior results across all industries. Whether you need custom hermetic circular connectors, circle hermetic connectors, or rectangular hermetic connectors compliant with MIL-Spec, we’re ready to meet your exacting needs. Contact Complete Hermetics today for expertly engineered hermetic products that perform under pressure.

Hermetic Feedthroughs for Precision Applications Across Industries

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Understanding Hermetic Feedthroughs

Hermetic feedthroughs serve a vital role in protecting electrical systems by enabling the safe transmission of current through vacuum-sealed or high-pressure environments. These components are engineered to maintain airtight integrity while offering dependable conductivity across a sealed barrier. Whether referred to as vacuum feedthroughs, electric feedthroughs, or glass to metal feedthroughs, their function remains the same: to deliver performance without compromising the enclosure’s hermetic seal.

Versatile Hermetic Products for Complex Systems

Today’s industries—from aerospace to medicine—require highly reliable hermetic products to function under demanding conditions. At the heart of these solutions are custom hermetic feedthroughs, including multi pin hermetic feedthroughs and electrical bulkhead assemblies, all crafted to withstand extreme temperatures and pressures. These configurations often feature laser-welded or solder-in installations, ensuring leak-free performance in mission-critical applications such as submersible pumps, cryogenic medical devices, and downhole instrumentation.

Advanced Materials: Glass and Ceramic Feedthrough Technologies

Two of the most trusted designs in hermetic sealing are glass to metal feedthroughs and ceramic to metal feedthroughs. These technologies are selected based on the application’s temperature tolerance, thermal expansion compatibility, and dielectric strength. Each solution is engineered to provide optimal sealing and longevity, especially where electrical continuity and environmental isolation are non-negotiable.

Why Choose Complete Hermetics?

At Complete Hermetics, precision and customization are our top priorities. We specialize in designing and manufacturing custom hermetic feedthroughs tailored to meet the exact specifications of your system. Whether you require a single electric feedthrough or a high-density electrical bulkhead, we offer both prototyping and full-scale production to support diverse sectors.

Explore the full line of hermetic products at Complete Hermetics—your trusted partner in high-performance sealing solutions. From glass to metal feedthroughs to robust multi pin hermetic feedthroughs, we provide engineering excellence for every challenge. 

Contact Complete Hermetics today to discuss your next project or request a custom solution designed for your unique application.

Hermetic Packages for Advanced Electronic Protection

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Innovative Hermetic Solutions for Harsh Environments

In industries where reliability and performance are paramount, hermetic products are vital for safeguarding electronic components from environmental damage. Hermetic packages are engineered to prevent the ingress of moisture, gases, and contaminants, ensuring long-term functionality in sectors such as aerospace, defense, telecommunications, and medical devices.

High-Performance Microwave and Hybrid Hermetic Packages

Complete Hermetics excels in crafting hermetic microwave and hybrid enclosures tailored for extreme conditions. These durable housings are specifically designed for use in military and space-grade applications where resistance to radiation, pressure, and temperature fluctuations is non-negotiable. With cutting-edge glass-to-metal and ceramic-to-metal sealing technologies, these enclosures deliver superior shielding and reliability, even in the most hostile environments.

Robust Hermetic Power Packages for Thermal Demands

For applications requiring efficient thermal management, hermetic power packages from Complete Hermetics offer unmatched stability and endurance. These enclosures are often fabricated using copper tungsten or copper molybdenum, which provide excellent heat dissipation. The precision sealing techniques ensure each package remains airtight under operational stress, supporting critical systems in power electronics, avionics, and defense infrastructure.

Versatile Telecom and Photonic Hermetic Enclosures

In the ever-evolving fields of fiber optics and telecommunications, hermetic products must adapt to both innovation and precision. Complete Hermetics designs photonic and telecom packages that are fully customizable to fit compact devices, high-speed optical components, and complex circuitry. These enclosures enhance signal integrity and extend the lifespan of sensitive systems, playing a crucial role in modern communication networks and medical imaging technologies.

Partner with Complete Hermetics for Unmatched Reliability

Whether your project involves high-frequency microwave circuits, high-power electronics, or miniaturized photonic modules, Complete Hermetics provides the expertise and technology to deliver premium hermetic packages. Every product is manufactured to the highest industry standards to meet your exact specifications.

Explore Complete Hermetics’ full range of hermetic products today and secure the reliability your systems deserve. From custom prototyping to large-scale production, we are your trusted partner for precision-engineered hermetic sealing solutions.  Contact us today to get started.

Leading Hermetic Manufacturer for Advanced Engineering Needs

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When reliability and precision are non-negotiable, industries across aerospace, defense, medical, and energy sectors turn to a trusted hermetic manufacturer. Hermetic technology plays a vital role in safeguarding sensitive electronic components from moisture, gas, and other environmental contaminants. This is where expertly engineered hermetic products become essential to mission-critical systems.

Comprehensive Hermetic Product Solutions

From hermetic seals and feedthroughs to hermetic connectors and hermetic packages, modern engineering requires versatile, high-performance solutions. These components are indispensable for protecting instrumentation in extreme conditions—whether in deep space or inside a life-saving medical device. Products such as battery end seals, hermetic headers, and vacuum viewports are built to withstand high pressure, temperature, and vacuum environments, ensuring operational integrity.

Precision Engineering of Hermetic Connectors and Headers

At the heart of many high-tech systems are hermetic connectors and hermetic headers, which maintain electrical integrity while preventing the ingress of gases or moisture. With custom design options and expert brazing and soldering techniques, these components are manufactured to exacting standards to meet unique application requirements.

Vacuum Viewports and Hermetic Feedthroughs for Specialized Applications

Vacuum viewports enable optical access in high-vacuum environments without sacrificing the integrity of the sealed system. Similarly, hermetic feedthroughs allow electrical or signal transmission while maintaining environmental barriers. These features are critical for scientific instruments, cleanroom systems, and advanced manufacturing processes.

Your Partner in Custom Hermetic Manufacturing

For over two decades, Complete Hermetics has provided engineered excellence as a premier hermetic manufacturer. As a wholly owned subsidiary of Aegis Technology Inc. in Santa Ana, CA, Complete Hermetics combines advanced prototyping with full-scale production capabilities. Whether you require hermetic products, hermetic packages, or custom hermetic seals and feedthroughs, our experienced team delivers precision-built components for your most demanding needs.

Contact Complete Hermetics today to discover how our innovative solutions can enhance the reliability and performance of your applications. We also specialize in hermetic connectors, vacuum viewports, and hermetic headers tailored to meet your exact specifications.

What Are Hermetic Seals Used For?

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Hermetic seals are critical components used in a wide range of industries, including aerospace, medical, and energy sectors. This article explores the diverse applications of hermetic seals and the expertise of Complete Hermetics in manufacturing these essential products.

Hermetic Products and Their Importance

Complete Hermetics is a leader in designing and manufacturing hermetic products, specializing in hermetic seals and feedthroughs. Their products ensure reliable protection against environmental conditions, making them indispensable in critical applications. These products include hermetic feedthroughs and glass to metal seals, designed to maintain integrity under extreme conditions.

Glass-To-Metal Seals

Complete Hermetics excels in producing glass-to-metal seals, which involve heating glass to a molten state and bonding it with metal. This process forms a robust seal that withstands drastic temperature changes and pressure variations, crucial for high-stress environments. Glass-to-metal seals are favored for their durability and cost-effectiveness, especially when compared to ceramic seals.

Ceramic-To-Metal Seals

Expanding their expertise, Complete Hermetics also offers ceramic to metal seals, known for their high-temperature resilience, reaching up to 600°C. These seals are perfect for applications requiring extreme thermal resistance, such as in high-performance aerospace components and advanced medical devices.

Types of Glass-To-Metal Seals

  1. Compression Seals: These are used when the coefficient of thermal expansion (CTE) of the metal exceeds that of the glass. The metal contracts around the glass as it cools, creating a high-pressure capable seal, often used in environments where pressure can reach up to 14,000 PSI.
  2. Matched Seals: These involve materials whose CTEs are closely matched, reducing stress in the glass and enhancing durability. Commonly used in electronic connectors, matched seals are preferred for their ability to handle thermal and mechanical shocks effectively.

Technological Advancements and Custom Solutions

Complete Hermetics doesn’t just follow industry standards; they set them. Their engineers custom-design seals and feedthroughs according to customer specifications, ensuring that each component meets the precise needs of their applications. Whether you need a solution for high-voltage applications or a custom configuration for medical equipment, Complete Hermetics has the capability and expertise to deliver superior hermetic products.

Connect with Complete Hermetics

If you’re in need of reliable hermetic seals or feedthroughs, look no further than Complete Hermetics. With a track record of excellence and innovation, they are equipped to handle the most challenging requirements. To find out more about their products and services or to discuss your specific needs, contact Complete Hermetics today. Engage with their team of experts to ensure your equipment remains protected and performs flawlessly in any environment.

Hermetic Packages: Shielding Critical Technologies

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In the realm of electronic component protection, hermetic sealing technologies have become indispensable. Complete Hermetics leads this field, providing tailored hermetic products that serve a multitude of critical sectors, including aerospace, defense, telecommunications, and healthcare.

Cutting-Edge Hermetic Microwave and Hybrid Enclosures

At Complete Hermetics, the focus is on developing top-tier hermetic microwave and hybrid packages. These packages are designed to endure extreme environmental conditions, making them ideal for aerospace and defense applications. By utilizing advanced materials and sealants, these hermetic enclosures offer unmatched resilience and reliability. The company’s engineering team works closely with clients to customize solutions that meet specific industry needs, ensuring superior performance and client satisfaction.

Sophisticated Hermetic Power Enclosures

Complete Hermetics has built a reputation on its robust hermetic power packages. With extensive experience in the field, these enclosures are engineered to accommodate the high thermal expansion common in power-intensive applications. Featuring materials such as copper tungsten and sophisticated sealing techniques involving glass-to-metal and ceramic-to-metal bonds, these power packages are built to ensure continuous, reliable operation under various thermal conditions. The collaborative approach taken by the engineering team helps align these solutions closely with customer expectations.

Customizable Photonic and Telecom Enclosures

In the dynamic sectors of photonics and telecommunications, Complete Hermetics provides versatile, hermetically sealed enclosures that protect everything from fiber optic packages to complex telecom systems. Whether the project is a small custom job or a large-scale production, the company offers scalable solutions that enhance system reliability and efficiency. This adaptive approach ensures that every client receives a hermetic sealing solution that is both effective and tailored to the specific challenges of the telecommunications and biomedical industries.

Complete Hermetics is committed to advancing the field of hermetic sealing by focusing on innovation, quality, and customer partnership. Our state-of-the-art hermetic packages are designed to exceed the stringent demands of modern electronic applications across various industries.

Explore the possibilities with Complete Hermetics and see how our advanced hermetic sealing solutions can safeguard your critical electronic components. Contact Complete Hermetics today to learn more about our products and services and how we can assist in achieving optimal operational excellence and customer satisfaction with our pioneering hermetic technologies.

Hermetic Headers: Pioneering Solutions for Advanced Electronic Applications

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Introduction to Hermetic Headers

Hermetic headers are critical components in the field of microelectronics, offering unparalleled protection in environments that require robust defense against external conditions. Complete Hermetics specializes in the production of high reliability hermetic headers and hermetic terminals designed to shield sensitive electronics from moisture, gas, liquid, pressure, vacuum, temperature, and corrosion.

Multi-Pin Headers: Ensuring Component Safety

Multi-pin headers from Complete Hermetics provide essential connectivity while maintaining the integrity of the seal in harsh environments. These headers are ideal for applications needing comprehensive protection, ensuring that each connection point remains secure against environmental challenges. The versatility of multi pin headers makes them perfect for a wide range of applications, from aerospace to medical devices, where failure is not an option.

Single-Pin Headers: Precision in Simplicity

Similarly, single pin headers offer a straightforward yet effective solution for applications requiring a single point of electronic contact. These components are built to the same rigorous standards as multi-pin variants, providing dependable performance under extreme conditions. Whether used in small consumer electronics or critical space-grade components, these headers guarantee that your devices operate flawlessly, regardless of external pressures or temperatures.

TO Headers:

Custom Solutions for Transistor Packaging TO headers, or transistor outline packages, represent a specialized category of hermetic sealing technology. Complete Hermetics excels in customizing these packages to fit a variety of microelectronic applications, including both transmitter side (TOSA) and receiver side (ROSA) configurations. The adaptability of TO headers makes them indispensable in the semiconductor industry, where precision and reliability are paramount.

Complete Hermetics: A Leader in Hermetic Technology

At Complete Hermetics, the commitment to quality is evident in every product. Our state-of-the-art manufacturing processes and rigorous quality control measures ensure that every hermetic header and terminal meets the highest standards of reliability and performance. Our expertise in hermetic sealing technology makes us a preferred partner for industries seeking solutions that offer complete protection against the most demanding environmental conditions.

Engage with Complete Hermetics Today

For industries and applications where failure is not an option, Complete Hermetics stands ready to deliver. Whether you require hermetic headers or hermetic terminals, our products are designed to meet your needs with precision. Contact us today to learn how our hermetic solutions can enhance the reliability and longevity of your electronic components. Visit our hermetic products page to explore our full range of products and start your journey towards perfect hermetic sealing.