MIL-SPEC Hermetic Connectors

Hermetic Connectors: Engineered Excellence for Extreme Environments

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In high-stakes industries such as aerospace, military, and advanced manufacturing, hermetic connectors are indispensable. These rugged, sealed interconnects maintain the integrity of mission-critical electronic systems by preventing the intrusion of gases, liquids, and moisture. As a key segment of hermetic products, these connectors are engineered for uncompromising performance under high pressure, elevated temperatures, and other severe operating conditions.

Custom Hermetic Connectors: Built for Precision

A leading hermetic connector manufacturer, Complete Hermetics offers a comprehensive range of custom hermetic connectors tailored to exact client specifications. Whether you require circle hermetic connectors or specialized variants for unique systems, our expertise in glass-to-metal and ceramic-to-metal sealing ensures long-term stability and protection. Materials such as Kovar, Stainless Steel, Titanium, and Aluminum are chosen for their superior sealing capability and compatibility with advanced applications, from avionics to semiconductor manufacturing.

Circle & Rectangular Hermetic Connectors for Versatility

For applications demanding round interconnects with compact yet robust construction, circle hermetic connectors are the preferred choice. These are available in solder-in or laser weld configurations, offering engineering teams flexibility in design and installation.

Rectangular hermetic connectors, including Sub D formats, are purpose-built for rugged defense, space, and industrial applications where space optimization and reliability are key. These rectangular models ensure secure integration into complex systems while delivering long-lasting hermetic protection.

MIL-Spec Hermetic Connectors: Trusted in Defense Systems

For the most demanding environments, MIL-Spec hermetic connectors—such as those adhering to MIL-DTL-38999 standards—are indispensable. Offering multiple shell sizes, coupling styles, and contact layouts, these connectors are designed for precision signal and power transmission in aerospace and military platforms. Complete Hermetics ensures full compliance with military specifications, making them a trusted partner in defense-grade connectivity.

Complete Hermetics: Your Hermetic Solutions Expert

When performance under pressure is non-negotiable, turn to Complete Hermetics. Our high-reliability hermetic products—from custom hermetic connectors to circle hermetic connectors  and advanced MIL-Spec hermetic connectors—deliver unmatched durability and sealing integrity. 

Contact Complete Hermetics today to find out how they can assist with your specific connector requirements and elevate the reliability of your critical equipment.

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.

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.

MIL-SPEC Hermetic Connectors

What Types of Hermetic Connectors Are Available?

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Hermetic connectors are crucial components in numerous applications, ensuring reliable operation in environments where air-tight sealing is a must. Complete Hermetics stands out as a leader in producing custom hermetic connectors, designed to meet stringent specifications in various demanding fields. Here’s a closer look at the range of options available and the innovations that set Complete Hermetics apart in the industry.

Innovative Designs and Materials

At the forefront of hermetic connector technology, Complete Hermetics offers an array of designs, including circular hermetic connectors and rectangular hermetic connectors. These connectors are not only versatile but also feature advanced materials like Kovar, Stainless Steel, Aluminum, and Titanium. The use of lightweight materials such as Aluminum and Titanium is particularly noteworthy, as these contribute to the overall durability and efficiency without compromising on quality.

Types of Hermetic Seals

Complete Hermetics specializes in hermetically glass sealed connectors and hermetically ceramic sealed connectors. These sealing techniques ensure maximum protection against environmental challenges. Glass seals are renowned for their robustness and superior insulation properties, making them ideal for harsh conditions. Ceramic seals, on the other hand, offer excellent thermal stability and resistance to thermal shock, enhancing the connectors’ reliability over a wide range of temperatures.

Applications and Installations

These hermetic connectors are engineered for resilience and longevity, accommodating both solder-in and laser weld installation methods. This flexibility in installation allows Complete Hermetics to cater to a broad spectrum of industries, from aerospace to the military. Their connectors are often specified in applications requiring MIL-Spec hermetic connectors, where adherence to military specifications is critical for performance and safety.

Complete Hermetics: Your Go-To Source for Hermetic Connectors

Whether your needs are for standard or custom hermetic connectors, Complete Hermetics is your trusted provider. With a focus on innovation and quality, their hermetic connectors are designed to perform flawlessly in the most challenging environments. If you’re looking for reliable, high-quality hermetic connectors, look no further than Complete Hermetics. Contact them today to find out how they can assist with your specific connector requirements and elevate the reliability of your critical equipment.

Custom Hermetic Feedthroughs

Hermetic Seals: The Airtight Solution for Critical Applications

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Hermeticity refers to the state of being airtight, ensuring no gases can penetrate through a sealed barrier. In interconnect applications, hermetic seals are essential for preventing gas leakage in pressure-sensitive environments, particularly through connectors. These innovative solutions are indispensable for industries where airtight technology safeguards the functionality and safety of vital equipment.

The Importance of Hermetic Feedthroughs

A fundamental application of hermetic technology lies in hermetic feedthroughs, which enable the secure transmission of power, signals, or fluids through pressure barriers. These components are meticulously designed to maintain system integrity, even in extreme conditions. From aerospace to medical devices, hermetic feedthroughs play a crucial role in ensuring reliable and safe operations.

Custom Hermetic Products Tailored to Your Needs

Complete Hermetics excels in providing custom hermetic products designed to meet diverse and specific industry requirements. Whether your project involves niche applications or large-scale production, their team delivers precision-engineered solutions. Their portfolio includes hermetically sealed connectors, hermetic terminals, and advanced glass-to-metal and ceramic-to-metal feedthroughs, ensuring unmatched performance and durability.

State-of-the-Art Manufacturing in Santa Ana, California

Located in the heart of California, Complete Hermetics leverages cutting-edge modeling and prototyping technologies to deliver superior-quality solutions. From custom designs for specialized projects to standardized components for high-volume needs, their advanced manufacturing processes ensure reliability and consistency in every product.

Why Choose Complete Hermetics?

As a global leader in producing hermetic packages and connectors, Complete Hermetics is committed to innovation, precision engineering, and customer satisfaction. Their expertise and dedication make them the trusted partner for industries requiring airtight interconnect solutions. With a proven track record of delivering high-performance products, they have earned a reputation for excellence worldwide.

Contact Complete Hermetics Today

For all your needs in hermetic seals and feedthroughs, and hermetically sealed connectors, trust Complete Hermetics to deliver exceptional quality and performance. Explore their innovative solutions to ensure your systems remain airtight and reliable. Contact their expert team today to discuss your project requirements. Complete Hermetics is your partner for airtight success!

Custom Hermetic Connectors

Custom-Made Hermetic Seal Connectors

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When it comes to ensuring the integrity of sensitive equipment, custom-made hermetic seal connectors are essential. These connectors provide a reliable sealing solution that protects against the infiltration of oxygen, bacteria, and moisture, making them ideal for various industries such as aerospace, automotive, medical, and offshore drilling.

Versatile Applications

At Complete Hermetics, we specialize in designing custom hermetic connectors tailored to meet specific mounting requirements. Our connectors are perfect for a range of applications, including submarines, offshore oil rigs, vacuum chambers, laboratory equipment, and military aircraft. By filling the gaps left by conventional connector manufacturers, we ensure that our clients receive the most effective hermetic sealing solutions.

Precision Engineering for Every Need

Whether you’re seeking Mil-Spec hermetic connectors for military applications or custom designs for older or unique equipment, Complete Hermetics delivers. We manufacture connectors that adhere to standards such as MIL-DTL-38999, MIL-C-5015, MIL-C-26482, and MIL-C-26500, ensuring your specifications are met without compromise.

Lightweight Solutions

We also offer lightweight options for our hermetic connectors. Our titanium hermetic connectors are renowned for their high resistance to temperature while remaining lightweight. On the other hand, aluminum hermetic connectors provide an extremely light overall weight, making them suitable for low-temperature applications across military, aerospace, and commercial sectors.

Tailored Manufacturing Options

Complete Hermetics can produce both circular and rectangular connectors with glass-to-metal and ceramic-to-metal seals. Our customers have the flexibility to specify the number of contacts, sizes, and shell styles, ensuring they receive the perfect hermetically sealed connectors for their needs.

The Complete Hermetics Advantage

Located in Santa Ana, California, Complete Hermetics is a global leader in specialized hermetic connectors. We provide custom designs, modeling, and prototypes to meet the diverse needs of our clients. From small-scale manufacturing to mass production, we can accommodate projects of any size.

Complete Hermetics is your one-stop source for all hermetically-sealed connectors, including glass-sealed and ceramic-sealed options. Contact us today to discover more about our custom-made hermetic seal products and standardized sizes.