Hermetic Seals and Feedthroughs for Extreme Environments

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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.

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Offshore Drilling Hermetic Solutions for Marine Equipment

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Protecting Systems Beneath the Surface

Offshore drilling hermetic solutions are essential for equipment exposed to saltwater, pressure fluctuations, and vibration. Subsea control modules, instrumentation, and power systems all rely on hermetic sealing to maintain performance and safety in one of Earth’s harshest environments.

Why Hermeticity Matters Offshore

At extreme ocean depths, water intrusion and corrosion can destroy unsealed electronics. Complete Hermetics designs glass-to-metal and ceramic-to-metal seals that prevent leaks even under thousands of PSI. Their seals resist electrochemical corrosion and ensure stable operation in deep-sea and high-salinity conditions.

Applications in Marine and Energy Industries

These hermetic components are used in offshore oil rigs, ROV sensors, subsea pumps, and oceanographic equipment. Their pressure-tested enclosures safeguard data acquisition and control systems used in deep-water exploration.

Engineering for Durability

Complete Hermetics utilizes titanium, Inconel, and stainless steel materials, chosen for their resistance to saltwater oxidation and mechanical fatigue. Each assembly undergoes hydrostatic and helium leak testing to confirm absolute reliability before deployment.

Custom Solutions for Every Project

Whether for shallow-water exploration or ultra-deep drilling, Complete Hermetics works directly with clients to create custom hermetic components optimized for subsea connectors, sensors, and power transmission.

Contact Complete Hermetics

Depend on Complete Hermetics for durable, corrosion-resistant offshore drilling hermetic solutions that protect your systems under the most demanding marine conditions.

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Reliable Electrical Feedthroughs for High-Voltage Systems

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Understanding Electrical Feedthroughs

Electrical feedthroughs are essential for transmitting power and signals through sealed or vacuum-tight walls while preventing any breach of hermeticity. They are widely used in scientific, aerospace, and industrial applications where reliable current flow must be maintained under vacuum, high voltage, or extreme temperature.

Design and Sealing Technology

Complete Hermetics uses advanced glass-to-metal and ceramic-to-metal bonding to produce leak-free, corrosion-resistant electrical feedthroughs. Each unit isolates conductors from metal housings, ensuring low resistance and high dielectric strength. The company’s process guarantees zero gas permeability and stability under mechanical stress.

Precision Engineering and Testing

Each feedthrough is designed with performance in mind. Options include single-pin and multi-pin configurations. All assemblies undergo vacuum testing, high-voltage dielectric checks, and pressure cycling to confirm absolute reliability before shipment.

Materials and Configurations

Complete Hermetics offers feedthroughs built from stainless steel, Inconel, or Kovar housings with ceramic insulators. Optional surface finishes—gold, nickel, or tin plating—enhance conductivity and solderability. These materials resist corrosion, heat, and wear, ensuring a long operational lifespan even in demanding conditions.

Industrial and Research Applications

  • Aerospace propulsion and flight-control systems
  • Semiconductor and vacuum-furnace environments
  • Particle accelerators and nuclear facilities
  • Medical imaging and diagnostic equipment

Contact Complete Hermetics

For dependable electrical feedthroughs that deliver precision, safety, and lasting performance, trust Complete Hermetics—your expert in high-integrity hermetic sealing.

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

Hermetic Feedthroughs for Precision Sealing Applications

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What Are Hermetic Feedthroughs?

Hermetic feedthroughs are specialized components that allow electrical current or signals to pass through an airtight barrier while maintaining a perfect seal. They are essential in industries like aerospace, defense, medical, and semiconductor manufacturing, where even microscopic leaks can compromise safety and performance. Designed with absolute precision, these feedthroughs maintain the stability of electrical systems under high vacuum, pressure, and temperature variations.

How Hermetic Feedthroughs Work

A hermetic feedthrough uses glass-to-metal or ceramic-to-metal sealing to create a molecular bond between conductive pins and their housing. This ensures gas-tight performance while electrically isolating the conductive elements. The result is stable electrical transmission in environments where ordinary connectors would fail due to temperature or atmospheric stress.

Custom Feedthrough Design

Complete Hermetics designs and manufactures custom hermetic feedthroughs for single-pin, multi-pin, RF, and high-voltage configurations. Each product is precisely engineered to meet customer-specific requirements for dielectric strength, mechanical endurance, and leak-rate performance. Every feedthrough undergoes helium leak testing (as low as 1 × 10⁻⁸ cc He/sec) to ensure consistent quality and compliance with industry standards.

Materials for Maximum Reliability

Using advanced materials such as stainless steel, Kovar, titanium, and high-grade ceramics, Complete Hermetics ensures excellent thermal stability, corrosion resistance, and electrical performance. Optional plating in gold, silver, or nickel further enhances conductivity and long-term reliability. These materials perform consistently across wide temperature and pressure ranges, making them ideal for mission-critical applications.

Applications Across Industries

  • Aerospace avionics, satellites, and flight controls
  • Semiconductor fabrication and vacuum chambers
  • Medical implants, imaging devices, and diagnostics
  • Defense and power generation systems

Contact Complete Hermetics

For high-precision hermetic feedthroughs engineered to deliver unmatched sealing performance, partner with Complete Hermetics—your trusted source for dependable interconnect technology.

Contact Info:

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

Offshore Drilling Hermetic Solutions for Extreme Environments

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Why Offshore Drilling Needs Hermetic Protection

In offshore drilling, equipment is exposed to saltwater, extreme pressure, and harsh environmental conditions. Offshore drilling hermetic solutions ensure reliable sealing to protect sensitive electronics, power systems, and sensors from failure in subsea and deep-water operations.

Applications of Hermetic Solutions Offshore

Hermetic seals and hermetic connectors are used in:

  • Subsea control systems
  • Offshore oil and gas platforms
  • Downhole drilling equipment
  • Marine and underwater monitoring systems

By preventing leaks and contamination, these solutions safeguard operations where downtime can lead to massive costs.

Complete Hermetics Offshore Solutions

Complete Hermetics manufactures custom hermetic seals, feedthroughs, and connectors designed specifically for offshore environments. Using glass-to-metal and ceramic-to-metal sealing technologies, their components deliver long-term durability under high pressure and corrosive marine conditions.

Key benefits include:

  • High resistance to saltwater corrosion
  • Protection against pressure changes and vibration
  • Long operational lifespan in subsea systems

Materials and Engineering for Harsh Conditions

By using stainless steel, titanium, and high-performance ceramics, Complete Hermetics ensures that its offshore drilling hermetic solutions perform reliably in the most demanding subsea applications. Their engineering expertise allows for both standardized designs and custom solutions tailored to customer requirements.

Contact Complete Hermetics

As a leader in offshore drilling hermetic solutions, Complete Hermetics provides customized hermetic seals, feedthroughs, and connectors to ensure maximum reliability in subsea operations.

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Hermetic Seals and Feedthroughs for Reliable Protection

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Why Hermetic Seals Are Important

Hermetic seals protect sensitive electronics from moisture, pressure, and gas leaks. In industries such as aerospace, defense, automotive, and medical, glass-to-metal seals and ceramic-to-metal seals provide airtight reliability where failure is not an option.

Complete Hermetics Seal Solutions

Complete Hermetics is a custom hermetic seal manufacturer specializing in glass-to-metal feedthroughs and ceramic-to-metal feedthroughs. Their engineers create custom prototypes and production-ready components to fit unique requirements across multiple industries.

Applications include:

  • Aerospace and defense electronics
  • High-voltage and vacuum systems
  • Medical devices, batteries, and sensors

Glass-to-Metal Seals

Glass is heated to a molten state and bonded to metal, creating a strong hermetic seal. These seals handle temperature changes, pressure variations, and corrosion resistance. Glass-to-metal feedthroughs are also cost-effective and versatile compared to ceramic alternatives. Options include compression seals for extreme pressure (up to 14,000 PSI) and matched seals for high thermal and mechanical shock resistance.

Ceramic-to-Metal Seals

For high-temperature, high-voltage, or harsh environments, ceramic-to-metal seals offer superior durability. While more labor-intensive to produce, they provide long-lasting performance in vacuum feedthroughs and electrical sealing applications.

Plating and Material Options

Complete Hermetics offers plating choices such as gold, silver, nickel, and tin to improve corrosion resistance and soldering capabilities. Materials include stainless steel, Inconel, Kovar, copper alloys, and high-performance ceramics, depending on application requirements.

Contact Complete Hermetics

As a leader in hermetic seals and feedthroughs, Complete Hermetics provides tailored solutions for both standard and custom designs. Whether you need glass-to-metal seals, ceramic-to-metal seals, or specialized hermetic feedthroughs, we deliver unmatched reliability.

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Vacuum Feedthroughs for Hermetic Sealing Solutions

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What Are Vacuum Feedthroughs?

Vacuum feedthroughs—sometimes called glass-to-metal feedthroughs or ceramic-to-metal feedthroughs—are essential components in hermetic sealing systems. They allow electrical current or signals to pass through airtight barriers without losing integrity.

Why Hermetic Feedthroughs Are Critical

The purpose of a hermetic feedthrough is to maintain a gas-tight seal while carrying electricity through a vacuum system. In aerospace, defense, semiconductor, and medical devices, even the smallest leak can lead to costly failures. Ensuring hermeticity keeps sensitive electronics safe from moisture, pressure changes, and environmental damage.

Complete Hermetics Vacuum Feedthroughs

Complete Hermetics manufactures both glass-to-metal feedthroughs and ceramic-to-metal feedthroughs. Their engineers design custom prototypes to meet specific requirements, from single-pin designs to high-voltage and RF feedthroughs. Applications include:

  • Aerospace and defense systems
  • Semiconductor equipment and vacuum chambers
  • Medical devices and diagnostic systems
  • High-voltage and power applications

Materials for Reliable Performance

Using durable materials such as stainless steel, Kovar, high-grade ceramics, and specialized glass, Complete Hermetics ensures long-lasting performance. These vacuum feedthroughs are engineered to handle extreme temperatures, vibration, and pressure, making them dependable across industries.

Contact Complete Hermetics Today for Your Hermetic Solutions

Complete Hermetics is a trusted leader in vacuum feedthroughs and hermetic sealing. Whether you need glass-to-metal or ceramic-to-metal solutions, our team delivers precision-engineered feedthroughs built to your exact specifications.

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Top 15 Frequently Asked Questions About Hermetic Seals and Feedthroughs

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Hermetic seals and feedthroughs are essential in industries that require airtight, corrosion-resistant, and high-temperature-capable components. From aerospace to medical devices, these components protect critical systems from environmental damage. Below are 15 top FAQs with concise answers to help you understand these vital technologies.

1. What is a hermetic seal?

A hermetic seal is an airtight and moisture-proof seal that prevents gas or fluid leakage between joined components.

2. What is a hermetic feedthrough?

A hermetic feedthrough allows electrical signals or power to pass through a sealed barrier without compromising the seal’s integrity.

3. What are glass-to-metal seals?

These glass-to-metal seals fuse molten glass with metal under controlled thermal expansion to create a strong, durable, and airtight bond.

4. What’s the difference between matched and compression seals?

Matched seals use materials with similar thermal expansion rates; compression seals use mismatched rates for higher strength and pressure resistance.

5. What applications use hermetic feedthroughs?

They are used in aerospace, military, medical implants, vacuum systems, and oil & gas instrumentation.

6. What materials are used in glass-to-metal seals?

Common materials include Kovar, stainless steel, Inconel, and alkali barium glass.

7. What’s the leak rate standard?

Complete Hermetics’ products meet or exceed 1×10⁻⁹ atm cc/sec He for superior hermeticity.

8. Are custom designs available?

Yes. Complete Hermetics offers fully customized solutions tailored to specific dimensions, materials, and electrical specs.

9. What are ceramic-to-metal seals used for?

For high-voltage, high-temperature, and corrosive environments that glass cannot withstand.

10. How do ceramic-doped glass seals differ?

They offer high thermal resistance (up to 600°C) at a lower cost than traditional ceramic-to-metal seals.

11. What plating options are available?

Platings include gold, silver, electroless nickel, and tin for corrosion resistance and solderability.

12. Can hermetic seals be used in medical devices?

Absolutely. Titanium terminals and headers are ideal for batteries, sensors, and diagnostic tools.

13. What electrical specs can be expected?

Typical insulation resistance exceeds 1 GΩ @ 100 VDC; dielectric strength depends on glass type.

14. What shapes and sizes are available?

Circular, rectangular, micro-D and custom headers are available across a wide range of standard and custom sizes.

15. Can feedthroughs handle high pressure?

Yes. Compression seals can withstand pressures up to 14,000 PSI, depending on design.

Why Choose Complete Hermetics?

Complete Hermetics is a leading custom manufacturer of glass-to-metal, ceramic-to-metal, and hermetic feedthroughs and seals. Our expert team designs hermetic connectors, headers, packages, and vacuum viewports to fit your exact requirements. Whether you’re in aerospace, defense, medical, or industrial sectors, we deliver high-performance, leak-proof solutions with precision and reliability.

📞 Phone: 714-265-1238
📧 Email: info@completehermetics.com
🔗 Contact Form: Complete Hermetics Contact

Contact Complete Hermetics today – your partner in precision sealing solutions.

Top Hermetic Manufacturer for Precision Sealing Solutions

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When searching for the top hermetic manufacturer, industry leaders and engineers alike turn to Complete Hermetics—a company known for delivering high-performance, custom-built hermetic products designed for reliability in extreme conditions. From critical aerospace systems to sensitive medical devices, Complete Hermetics offers advanced solutions built to exacting standards.

Unmatched Expertise in Hermetic Sealing Technologies

At the heart of Complete Hermetics’ success is their mastery in developing both glass-to-metal seals and ceramic-to-metal seals. These precision-engineered solutions are critical for maintaining airtight protection in environments where performance, longevity, and safety cannot be compromised. Whether the application involves high pressure, fluctuating temperatures, or corrosive atmospheres, these hermetic seals ensure lasting integrity.

Comprehensive Hermetic Product Line

Complete Hermetics manufactures a full range of hermetic feedthroughs, hermetic connectors, and hermetic headers to meet stringent industry demands. These components are designed for mission-critical performance in sectors such as aerospace, defense, energy, communications, and semiconductors. The company’s hermetic packages are customized to maintain electrical performance and mechanical stability while preventing any leakage or contamination.

From small prototypes to large-scale assemblies, every part is meticulously tested for durability, electrical insulation, and leak tightness. The result? Industry-trusted components that consistently exceed expectations.

Advanced Manufacturing and Materials Integration

Beyond sealing components, Complete Hermetics offers in-house brazing and soldering to create seamless assemblies that support complex design needs. The company’s innovation in materials science, combined with tight quality control, allows it to deliver robust hermetic products such as vacuum viewports, battery end seals, and high-voltage hermetic feedthroughs tailored to your specifications.

Choose Complete Hermetics – Built for Your Application

Complete Hermetics is a custom manufacturer of glass-to-metal, ceramic-to-metal, hermetic seals, and hermetic feedthroughs. Our expert team works closely with clients to design and develop hermetic connectors, hermetic packages, hermetic headers, and more—ensuring every component meets your project’s unique requirements.

📞 Phone: 714-265-1238
📧 Email: info@completehermetics.com
🔗 Contact Form

Trust Complete Hermetics to deliver solutions that seal your success.

What Are Defense Hermetic Feedthroughs Used For?

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Hermetic feedthroughs in defense applications play a crucial role in ensuring secure, reliable electrical connections across pressurized or vacuum-sealed barriers. These precision-engineered components maintain airtight integrity while transmitting electrical signals or power, making them indispensable for high-performance environments like defense electronics, aerospace, naval systems, and other mission-critical applications. By preventing moisture, gases, and contaminants from breaching the sealed enclosure, hermetic seals preserve the integrity and longevity of sensitive electronics.

Custom Hermetic Feedthroughs Built for the Defense Industry

From radar systems and drones to underwater surveillance equipment, today’s military technologies demand highly robust, custom hermetic feedthroughs that perform under extreme conditions. Complete Hermetics specializes in designing tailored solutions—including multi-pin hermetic feedthroughs and electrical bulkhead hermetic feedthroughs—to fit specific environmental and performance needs.

Whether it’s enduring high pressures in submersible defense systems or maintaining electrical continuity in aircraft sensor arrays, our hermetic solutions are engineered to withstand temperature extremes, vibration, and corrosion. Laser-welded assemblies and vacuum-grade sealing ensure absolute reliability and zero leakage in any scenario.

Advanced Materials: Glass-to-Metal and Ceramic-to-Metal Seals

The right choice of materials is essential for optimal performance. At Complete Hermetics, we offer both glass-to-metal and ceramic-to-metal feedthroughs. Glass provides excellent hermeticity and thermal compatibility, while ceramic excels in high-voltage and high-frequency applications. Our engineers work closely with clients to choose the best configuration for durability, dielectric strength, and mechanical stability.

Complete Hermetics: Innovating Hermetic Technology

Complete Hermetics is a trusted custom manufacturer of glass-to-metal, ceramic-to-metal, hermetic seals, and hermetic feedthroughs. We bring decades of technical expertise to help you design and develop the perfect hermetic connectors, hermetic packages, hermetic headers, vacuum viewports, and more—each solution tailored to your application.

Whether your project requires prototyping or full-scale production, we deliver the quality, performance, and customization you need. Let us help you keep your systems protected and fully operational—anywhere in the world.

📞 Phone: 714-265-1238
📧 Email: info@completehermetics.com
🔗 Contact Form: https://www.completehermetics.com/contact-us/
🌐 Website: www.completehermetics.com

Explore solutions with Complete Hermetics—the leader in defense hermetic feedthroughs and sealing innovation.