Hermetic Feedthroughs: Essential for Sealing and Electrical Connectivity

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Hermetic feedthroughs are vital components used to transmit electrical current through a hermetically sealed or vacuum system. The term “hermetic” refers to a state of being completely air or gas-tight, ensuring that no gases pass through pressure barriers. These specialized connectors play a critical role in industries requiring high-performance sealing and connectivity, such as aerospace, medical devices, and energy sectors.

Custom Hermetic Feedthroughs for Specialized Applications

Complete Hermetics specializes in designing and manufacturing custom hermetic feedthroughs to meet specific client requirements. Whether it’s a glass-to-metal or ceramic-to-metal design, these custom feedthroughs are tailored for applications that demand exacting specifications, including the most extreme environments. The customization process includes working with unique materials and advanced manufacturing techniques to ensure that each feedthrough offers the highest level of performance.

Our custom solutions have been used in various industries, from submersible pumps and downhole instrumentation to cryogenic medical probes. For complex or multi-functional systems, multi-pin hermetic feedthroughs are available to provide multiple connection points while maintaining an air-tight seal.

Electrical Bulkhead Hermetic Feedthroughs: Strength and Durability

Electrical bulkhead hermetic feedthroughs are another key product offered by Complete Hermetics. These feedthroughs provide multiple electrical connection points through a single bulkhead flange, optimizing both space and functionality. They are specifically designed to handle extreme conditions, such as high pressure in downhole drilling or the precision required for surgical instruments. By maintaining reliability and continuity of electrical power, these bulkhead feedthroughs ensure that critical systems continue to function even in the harshest environments.

Comprehensive Hermetic Solutions

Complete Hermetics is committed to providing the most advanced solutions for all hermetic sealing needs. The terms vacuum feedthrough, electrical feedthrough, glass feedthrough, or glass-to-metal feedthrough, and ceramic feedthrough or ceramic-to-metal feedthrough are often used interchangeably in the vacuum and hermetic sealing industries. At Complete Hermetics, we offer a broad range of feedthrough options, from standardized sizes to fully customized prototypes, ensuring your system operates smoothly and securely.

Contact Complete Hermetics today to learn more about our comprehensive product offerings and custom designs for your industry’s unique requirements.

A Quick Primer on Hermetic Seals and Feedthroughs

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As you may know, hermetic feedthroughs allow energy or substances to migrate from outside a hermetically-sealed area to the inside. Maintaining hermetic seals is important with a feedthrough, but providing electrical isolation is also key. Strict performance standards call for no leakage while ensuring that a powerful vacuum remains.

Constructing Hermetic Feedthroughs

A hermetic feedthrough is created using similar techniques to creating hermetic seals. Its glass-to-metal construction incorporates molten glass that can be bonded tightly to metal. To achieve this feat, the glass must be heated to between 1,400 and 1,600 degrees Celsius. Some feedthroughs incorporate ceramic-to-metal or electrical sealing. Hermetic feedthroughs can fall into one of three unique categories:

  • Low-voltage
  • Water-cooled/RF
  • High-voltage

Critical Performance Standards

A high-quality feedthrough can resist extreme temperature shifts, changes in pressure and huge swings in humidity levels. When plated, feedthroughs can also resist corrosion and handle wire bonding or soldering. Depending on product specifications, a feedthrough may need to tolerate even more extremes without so much as a tiny amount of leakages. For feedthroughs used in medical equipment, such super-strict production standards are necessary.

Complete Hermetics develops and manufactures hermetic seals and feedthroughs that deliver the dependability and durability needed in your applications. Besides our standard feedthroughs, we can also design custom versions that meet your needs. Call us at (714) 265-1238 or fill in the contact form for your needs  of hermetic seals and feedthroughs now.

Custom Hermetic Feedthroughs

What Are Electrical Feedthroughs For?

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You might not think that there are many components that can be found in X-ray machines, transformers and furnaces. But electrical feedthroughs are commonly used in a wide variety of technologies to help make sure that electricity doesn’t escape and cause malfunctions. It is important to know what these feedthroughs are used for and to appreciate this important piece of technology that keeps so many different technologies running.

The Importance of Vacuums 

Creating a vacuum guarantees that the electricity being transported from one part of a machine to another does not get out. Vacuum feedthroughs effectively make sure that the electricity is distributed safely.

Using Seals

The key to creating a vacuum is the type of seal that is used. Hermetic feedthroughs use glass-to-metal seals and ceramic seals to create this vacuum. When building a new seal, it is extremely important that the materials used are able to withstand intensive use and not break down over time.

This is why many seals are made with glass and ceramics; these materials are designed to withstand extreme temperatures, as well as other wear and tear. Many of these seals are used in technology like furnaces that operate at extreme temperatures. Making sure the seals do not break down easily will make sure the machine runs smoothly.

The Creation of Hermetic Feedthroughs

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Hermetic feedthroughs are designed specifically to all some substances or energy to pass from inside or outside a hermetically-sealed area to the other side. The feedthroughs must deliver both hermeticity and electrical isolation. They must be secure enough to prevent even the smallest degree of leakage while maintaining a powerful vacuum. There are three main types of hermetic feedthroughs: low voltage, water-cooled and RF (high frequency), and high-voltage feedthroughs. Applications for these items include furnaces, analysis equipment, satellite instrumentation, particle accelerators, and X-ray equipment.

How Is the Hermetic Seal Achieved?

How are hermetic feedthroughs achieved? When a glass-to-metal hermetic feedthrough is desired, industry leaders use high temperatures to melt glass to the point that they can be tightly bonded to metal. When done correctly, these feedthroughs can be used in applications such as those involved in electrical situations. These products are highly resistant to dramatic temperature changes, as well as fluctuations in pressure and humidity. Many of these products are plated to resist corrosion as well as improving the items capacity for wire bonding or soldering. Naturally, the pin and body formation of some hermetic feedthroughs require even tougher standards of excellence. This is the case for items destined to be found in medical equipment, especially used in diagnosis and sensing.

Choosing the Right Hermetic Feedthrough and Seal

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Although you’ve developed a system that requires a hermetic feedthrough and seal, you may not have the knowledge and experience to fully know what type of system and materials should be used to be most effective when your product is in use. Our engineers specialize in hermetic feedthroughs and seals in many different industries to help you move forward with your project.

There are many different ways to create the vacuum and hermetic feedthrough. In a glass-to-metal seal, the methodology of design and development depend on multiple factors. There are plating capabilities which let the hermetic seal work better under different conditions. If your project operates under higher voltage or temperatures, a ceramic-to-metal application may the right product to fit your needs. Because we have worked with medical, military, optics, and aerospace organizations, we have the depth of knowledge to design a prototype to meet your specifications.

Discuss your project with our engineers to find the perfect hermetic feedthrough and sealing system that matches your industry. We design and manufacture custom products that work under specific conditions. Our products are tested before use to ensure the reliability of the seal and feedthrough. We understand that you need the materials to fit the scope and scale of the project while managing your budget. Contact us and let us help.

What Kind of Hermetic Feedthrough Should You Choose?

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You rely on a steady connection of power to get jobs done in the most hostile climates, and you need a hermetic feedthrough that you can rely upon. There are several kinds of feedthroughs available, so look carefully before selecting.

Glass to Metal

A glass to metal hermetic feedthrough is made of glass which is heated up and used in its molten state. This is a durable feedthrough that can operate under all conditions and transfer electricity at high voltages.

Ceramic to Metal

Ceramic to metal hermetic feedthroughs require a substantial amount of craftsmanship and time to make. They can be custom-made for specific uses and are ideal for jobs that require a certain kind of feedthrough.

Look for Quality

Whatever kind of hermetic feedthrough you use, make sure you are purchasing one that is made of high-quality materials with construction that prevents all kinds of leaks. Heavy duty feedthroughs are often used in the military and for medical uses and provide a reliable seal and connection time after time. Check your hermetic feedthrough periodically for signs of wear and tear and be sure to replace as needed. The highest-quality feedthrough are virtually leak resistance and will never fail to deliver.

Glass-to-Metal Seals and Feedthroughs

When To Choose Glass-to-Metal Feedthroughs

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Feedthroughs are an indispensable part of most commercial electrical applications and their accuracy is critical to its success. When working in aerospace, defense and other arenas where extreme conditions are the norm and high reliability is vital, feedthrough performance is even more vital. These are cases where glass to metal hermetic feedthroughs make the most sense. Here are a few other applications where glass-to-metal sealed feedthroughs are the ideal choice.

Medical Applications

Perhaps no environment could be tougher than the human body. When a device must be implanted, a glass-to-metal hermetic feedthrough is the best choice. This type of airtight feedthrough prevents diffusion of gasses and keeps electrical components from corroding when doing so could spell life or death.

Automotive Applications

If a sensor has ever triggered your vehicle’s check engine light, you know how important it is that they work properly. Glass-to-metal feedthroughs are ideal to ensure sensors measuring everything from flow to pressure can function properly.

Industrial Applications

Glass-to-metal seal feedthroughs are commonly used in critical industrial applications, blocking the effects of high temperature and damaging chemicals. In this case, hermetic feedthroughs can also prevent electronic failure caused by humidity or pressure.

Hermetic feedthroughs have countless applications in defense, medical, aerospace, and other fields. Glass-to-metal manufacturing creates the most reliable performance.

Getting the Right High Vacuum Feedthrough

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A hermetic feedthrough must be secure enough to prevent leakage, even the smallest amount. It has to maintain a vacuum under certain conditions, which are different for every application. Fortunately, there are three main types of feedthroughs which operate in hermetic vacuums:

  • Low voltage
  • Water-cooled and RF
  • High-voltage

We have the experience to design and develop a high vacuum feedthrough to achieve the proper hermetic seal for your application. Let us work within your specifications to create what you need to move forward with your system.

Attaining a hermetic seal with a high vacuum feedthrough can be done using a glass-to-metal or ceramic-to-metal design. The properties of your project and its use will determine the best materials for its design. We have multiple options to meet the standards of excellence in your industry. Our engineers specialize in developing the right hermetic system to fit your needs.

Because we have worked with many different industries, we know how to create the product that fits medical equipment or satellite systems. Our engineers have worked with the military, aerospace development, and pharmaceutical companies. Every hermetic system with a high vacuum feedthrough is tested before use to ensure quality control. Whether you’re looking for a prototype or manufacturing of multiple hermetic seals, our team can make it happen.