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.

Custom Hermetic Solutions for Mission-Critical Applications

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In high-stakes industries like aerospace, defense, semiconductors, and medical devices, custom hermetic solutions are not optional—they’re essential. The integrity of sensitive electronic systems depends on the performance of components that can resist moisture, gas, and extreme environmental conditions. That’s where hermetic seals and hermetic connectors come in—providing the airtight barrier necessary to ensure uninterrupted functionality in the harshest settings.

Engineered for Precision: Custom Hermetic Feedthroughs and Headers

Not all applications are the same, and neither are their sealing requirements. Complete Hermetics specializes in manufacturing hermetic feedthrough assemblies and hermetic headers designed for exacting specifications. Using materials such as Kovar, stainless steel, titanium, and aluminum, they offer glass-to-metal and ceramic-to-metal seals that meet rigorous performance standards. These materials not only deliver superior corrosion resistance and thermal durability but also maintain electrical isolation—an absolute must in high-reliability sectors.

Hermetic Connectors for Harsh Environments

From hermetic connectors that meet MIL-DTL-38999 specs to custom configurations in circular or rectangular formats, Complete Hermetics ensures connectivity without compromise. These connectors support a wide range of shell sizes and pin layouts, enabling seamless integration into aerospace control systems, satellite payloads, and advanced industrial automation setups. Each connector is leak-tested to meet or exceed helium leak standards, safeguarding your mission-critical assets against contamination and failure.

The Role of Hermetic Packages in System Longevity

Beyond connectors and headers, hermetic packages provide a complete enclosure solution for sensitive electronics. These airtight casings shield circuits and sensors from environmental hazards, including temperature fluctuations, vibration, and corrosive chemicals. Complete Hermetics crafts these packages with the same high standards that govern all of their hermetic product lines, ensuring consistent protection and performance.

Partner with Complete Hermetics Today

Whether you’re upgrading a defense system, designing advanced medical instrumentation, or building next-gen aerospace controls, trust Complete Hermetics for unmatched quality and customization in hermetic seals, hermetic feedthrough, hermetic connectors, hermetic packages, and hermetic headers. Their engineering team collaborates with you from concept to completion to deliver solutions that excel under pressure—literally.

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

The Role of Hermetic Feedthroughs in Enabling Reliable Sealed Systems

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In mission-critical applications—ranging from aerospace to medical devices—hermetic feedthroughs ensure that electrical signals pass through sealed barriers without compromising environmental integrity. These components protect sensitive electronics from gas, liquid, or pressure intrusions, maintaining functionality in extreme environments.

Engineered for Harsh Conditions

Designed for rugged conditions, hermetic products such as multi-pin hermetic feedthroughs and electrical bulkhead hermetic feedthroughs are built to endure high-pressure and high-temperature situations. In downhole instrumentation, submersible pumps, and cryogenic medical devices, these feedthroughs maintain electrical continuity even in the harshest conditions. Whether installed via soldering or laser welding, their durability supports continuous performance in deep drilling and implantable surgical systems.

The Science Behind Hermetic Sealing

The term “hermetic” refers to the state of being airtight—an essential property for devices operating in vacuum or pressure-regulated environments. Technologies like glass to metal seals and ceramic to metal seals prevent leakage and shield electronics from moisture, gas, or contamination. These seals are integral to hermetic connectors, which bridge power and signal paths without compromising the enclosure’s integrity.

Custom Solutions for Complex Designs

Every application is unique, which is why custom hermetic feedthroughs and hermetic headers are in high demand. Engineers require flexibility in design and performance, and Complete Hermetics delivers both. With a wide range of materials and configurations, they produce components tailored to your specifications—ensuring precision and reliability across all industries.

Choose Complete Hermetics for Sealing Excellence

As a premier hermetic seal manufacturer, Complete Hermetics combines advanced manufacturing, rigorous leak testing, and unmatched engineering expertise to deliver world-class hermetic products. Their glass to metal seals, ceramic to metal seals, and hermetic connectors are trusted by professionals in energy, medical, aerospace, and industrial sectors.

Partner with Complete Hermetics for custom-engineered solutions that protect your systems from the inside out. Contact Complete Hermetics today to start your next high-performance sealing project.

Top-Rated Hermetic Seal Manufacturer for Reliable Electronic Protection

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Why Hermetic Products Matter in Modern Electronics

When it comes to ensuring long-term performance in mission-critical systems, hermetic products are essential. They shield sensitive electronics from moisture, gases, and contaminants that can compromise functionality. From aerospace and defense to telecom and medical devices, the need for reliable, airtight protection is more vital than ever.

Advanced Glass to Metal Seals & Ceramic to Metal Seals

The use of glass to metal seals and ceramic to metal seals enables robust protection in the harshest environments. These advanced sealing methods maintain electrical conductivity while ensuring a complete hermetic barrier. Whether in low-earth orbit satellites or implantable medical devices, these seals preserve performance under high pressure, radiation, and extreme temperature swings.

Customized Hermetic Connectors and Feedthroughs

Precision matters when it comes to interconnectivity. That’s why hermetic connectors and custom hermetic feedthroughs are indispensable in complex electronic systems. Designed to resist corrosion and maintain high electrical isolation, these components ensure seamless signal and power transfer without compromising environmental protection.

High-Performance Hermetic Headers and Power Packages

For high-voltage or high-temperature applications, hermetic headers and power packages built from materials like copper tungsten or molybdenum provide exceptional thermal dissipation. These packages support avionics, radar, and defense systems that operate in unforgiving conditions. Sealed with cutting-edge technologies, they maintain structural integrity and airtightness under stress.

Tailored Hermetic Enclosures for Telecom and Photonics

The growing demands of 5G networks, photonic devices, and optical systems require compact, high-frequency-compatible hermetic enclosures. Complete Hermetics delivers scalable, precision-engineered designs that maintain signal clarity and extend system life in high-speed communications, LIDAR, and imaging systems.

Choose Complete Hermetics: Your Trusted Hermetic Seal Manufacturer

At Complete Hermetics, we don’t just manufacture components—we engineer reliability. Whether you’re prototyping a custom module or scaling for production, we offer full-service solutions including glass to metal seals, custom hermetic feedthroughs, and hermetic connectors. Every part is rigorously tested to exceed industry standards for leak rate, insulation resistance, and thermal performance.

Explore our full line of hermetic products today. As a leading hermetic seal manufacturer, Complete Hermetics is ready to partner with you to deliver precision, durability, and peace of mind. Contact us now to begin your next high-reliability project.

Ceramic to Metal Brazing - Soldering

Ceramic to Metal Brazing Solutions for Hermetic Sealing Applications

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What is Ceramic to Metal Brazing?

Ceramic to Metal Brazing is a specialized joining technique that bonds ceramic components to metal parts, offering unmatched durability, biocompatibility, and resistance to extreme environments. Widely used in medical devices, laser assemblies, microwave tubes, and electrical feedthroughs, this method provides high joint strength for vacuum, high voltage, and high-pressure conditions. With growing demand in aerospace, defense, and biomedical sectors, this technology is becoming essential for advanced engineering systems.

Key Materials & Brazing Processes

Brazing ceramics like Polycrystalline Alumina (94%-99%), Sapphire, BeO, Si3N4, AlN, and ZrO2 to metals such as Kovar, Molybdenum, Titanium, Inconel, and Nickel Alloys requires precision. Common brazing methods include:

  • Vacuum Brazing
  • Active Metal Brazing
  • Hydrogen Brazing
  • Reactive Air Brazing

The choice of braze alloy—gold, silver, copper or their alloys—depends on application-specific requirements for conductivity, strength, and corrosion resistance. Pre-metallization through Mo/Mn thick film or sputtering thin film enhances bond quality and reliability.

Custom Hermetic Products for High-Reliability Systems

When creating mission-critical systems, ensuring a hermetic seal is paramount. Solutions such as hermetic connectors, glass to metal seals, ceramic to metal seals, and hermetic headers are all vital components in devices requiring long-term performance in harsh environments. Whether for implantable medical devices or satellite communication modules, these hermetic products protect sensitive electronics from moisture, pressure shifts, and chemical exposure.

Complete Hermetics: Your Trusted Hermetic Seal Manufacturer

As a leading hermetic seal manufacturer, Complete Hermetics offers extensive expertise in custom hermetic feedthroughs, ceramic to metal brazing, and full-cycle prototype development. Their capabilities span modeling and simulation, fixture design, and stress/failure analysis, ensuring dependable solutions for even the most demanding applications. All assemblies are meticulously tested for leak rates as low as 1×10⁻⁸ cc He/sec and meet stringent reliability standards.

Get Started with Complete Hermetics Today

Partner with Complete Hermetics for your next advanced assembly project. Whether you’re designing for medical, military, or industrial applications, their engineering team is ready to help.

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

Hermetic Seals: Custom Solutions for Harsh Environments

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The need for absolute containment, insulation, and durability in high-performance sectors drives the demand for reliable hermetic seals.  These components are critical to maintaining system integrity under extreme conditions such as pressure fluctuations, high temperatures, and corrosive environments. As a trusted hermetic seal manufacturer, Complete Hermetics delivers precision-engineered solutions in both glass-to-metal seals and ceramic-to-metal seals, customized for your specific application.

Glass-to-Metal Hermetic Seals

Glass-to-metal hermetic seals are the industry standard for cost-effective, high-strength, and corrosion-resistant protection. These seals are used in a wide range of hermetic products including electrical feedthroughs, vacuum systems, and RF or microwave applications. Complete Hermetics fabricates both compression and matched seals:

  • Compression Seals: Ideal for high-pressure use, with thermal expansion properties engineered for strength.
  • Matched Seals: Used when the coefficient of thermal expansion is closely aligned between materials, often in microelectronic and medical applications.

Our glass-to-metal hermetic feedthroughs are plated for enhanced corrosion resistance and electrical performance, with finishes like gold, silver, and nickel.

Ceramic-to-Metal Hermetic Feedthroughs

Where higher temperatures or voltages are required, ceramic-to-metal seals outperform their glass counterparts. At Complete Hermetics, we design and manufacture custom ceramic-to-metal feedthroughs and hermetic seals for use in aerospace, medical devices, and industrial power systems.

We also offer ceramic-doped glass seals—an advanced option that supports extreme heat tolerance up to 600°C, providing a lower-cost alternative to traditional ceramic sealing methods while maintaining high reliability.

Your Partner in Custom Hermetic Solutions

Whether your project requires miniaturized electrical feedthroughs or rugged hermetic connectors, Complete Hermetics has the expertise and flexibility to deliver. We specialize in custom hermetic seals and feedthroughs using advanced materials and tight manufacturing tolerances.

Connect with Complete Hermetics Today

If you’re looking for industry-leading performance and reliability, trust Complete Hermetics, your dedicated hermetic seal manufacturer. We provide customized, high-quality hermetic products to meet any challenge. Get in touch today to discuss your specific needs for glass-to-metal or ceramic-to-metal hermetic seals and feedthroughs.

Hermetic Seals for High-Reliability Applications

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When it comes to ensuring absolute containment in harsh conditions, hermetic seals are indispensable. These highly specialized components are critical in a range of demanding industries—from aerospace and defense to medical and energy systems. As a leading hermetic seal manufacturer, Complete Hermetics delivers tailored solutions through its extensive line of hermetic products, including glass-to-metal seals, ceramic-to-metal seals, and advanced custom hermetic seals and feedthroughs.

Excellence in Glass-to-Metal Sealing

Glass-to-metal seals are widely used for their exceptional insulation properties, pressure resistance, and cost-efficiency. Using precisely engineered thermal expansion matching techniques, Complete Hermetics fabricates both compression and matched seals, capable of withstanding extreme temperatures, rapid pressure changes, and corrosive environments. These seals can achieve hermeticity rates up to 1 x 10⁻⁹ atm cc/sec He and insulation resistance exceeding 1 GΩ @ 100 VDC—ideal for electrical feedthroughs, RF, and microwave applications.

Complete Hermetics also offers a variety of plating options, including gold, silver, electroless nickel, and tin, to enhance corrosion resistance and bonding characteristics.

Advanced Ceramic-to-Metal Seals

For more rugged environments where glass-to-metal seals fall short, Complete Hermetics specializes in ceramic-to-metal seals. These are engineered for high-voltage, high-temperature, and high-pressure applications—such as vacuum chambers, aerospace modules, and diagnostic equipment. Though more labor-intensive, ceramic seals excel in endurance, offering extended reliability in temperatures up to 600°C when using our ceramic-doped glass innovation.

Customized Engineering and Sealing Innovation

Whether you need a hermetic solution for microelectronics, medical devices, or military systems, Complete Hermetics works directly with clients to design custom hermetic seals and feedthroughs that meet exact performance specifications. From titanium terminals for battery systems to high-reliability hermetic connectors, our engineering team delivers unmatched precision.

Engage Complete Hermetics for Your Hermetic Solutions

For expertly crafted hermetic products built to survive the toughest conditions, trust the expertise of Complete Hermetics. As a premier hermetic seal manufacturer, we’re ready to design the most reliable glass-to-metal and ceramic-to-metal seals on the market. Contact Complete Hermetics today to discuss your custom requirements and discover innovative solutions for your sealing challenges.