Vacuum Feedthroughs and Bulkhead Hermetic Solutions

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Why Vacuum Feedthroughs Are Critical

Vacuum feedthroughs are specialized hermetic components that allow electrical power or signals to pass through vacuum or pressure barriers without leakage. Even microscopic leaks can compromise vacuum integrity, contaminate sensitive processes, or disrupt system performance. As a result, vacuum feedthroughs are essential in applications requiring precise environmental control.

High-Vacuum and Bulkhead Designs

Hermetic bulkhead feedthroughs provide multiple electrical pathways through a single flange-mounted interface. This design reduces the number of enclosure penetrations, improving system reliability and simplifying installation. Bulkhead feedthroughs are commonly used in high-vacuum chambers, pressure vessels, and sealed instrumentation housings.

Material Compatibility and Precision Engineering

Vacuum feedthroughs are manufactured using materials such as stainless steel, Kovar, titanium, and high-purity ceramics to ensure compatibility with vacuum environments. These materials exhibit low outgassing, excellent thermal stability, and corrosion resistance. Precision manufacturing and sealing techniques are required to meet stringent leak-rate specifications, often verified through helium leak testing.

Performance in Sensitive Systems

In vacuum systems, performance margins are extremely narrow. Feedthroughs must maintain electrical insulation, mechanical stability, and hermetic integrity under thermal cycling, vibration, and pressure differentials. Poorly designed feedthroughs can lead to system downtime, safety risks, or costly repairs.

Critical Applications

Vacuum feedthroughs are widely used in semiconductor fabrication equipment, aerospace simulation chambers, research laboratories, medical imaging systems, and high-energy physics instrumentation.

Contact Complete Hermetics Today for Your Hermetic Solutions

Complete Hermetics designs and manufactures custom vacuum feedthroughs and hermetic bulkhead feedthroughs, including multi-pin configurations, glass-to-metal and ceramic-to-metal seals, and vacuum-rated assemblies. The company also supplies hermetic connectors, headers, hermetic packages, and battery end seals to support fully integrated systems. With rigorous testing and precision engineering,  Complete Hermetics delivers vacuum solutions customers can depend on.

Hermetic Packages for Semiconductor and High-Reliability Electronics

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Purpose of Hermetic Packages

Hermetic packages are designed to protect sensitive electronic and semiconductor components from moisture, contaminants, pressure, and environmental stress. Even small amounts of moisture or oxidation can significantly degrade electronic performance, making hermetic packaging essential for long-term reliability in critical systems.

Semiconductor and Power Packaging

Semiconductor hermetic packages are commonly used for RF modules, MEMS sensors, laser diodes, photonic devices, and high-speed electronics. Hermetic power packages support high-current and high-voltage applications, incorporating robust materials and sealing technologies to handle thermal and electrical loads safely and efficiently.

Thermal Management and Materials

Hermetic packages often integrate materials such as copper tungsten, copper molybdenum, Kovar, stainless steel, and ceramics to balance heat dissipation with structural stability. Effective thermal management is critical to maintaining performance and preventing premature device failure, especially in power and RF applications.

Environmental Isolation and Stability

By creating a controlled internal environment, hermetic packages prevent moisture absorption, oxidation, and contamination. This isolation helps preserve calibration accuracy, signal integrity, and electrical stability over the product’s lifespan. Hermetic packaging also supports long-term storage and deployment without performance degradation.

Integration and High-Density Designs

Modern hermetic packages may incorporate multiple electrical feedthroughs, RF connectors, or optical windows while maintaining airtight integrity. These integrated designs allow complex electronic assemblies to operate reliably in compact form factors.

Contact Complete Hermetics

Complete Hermetics manufactures hermetic packages for semiconductor, RF, photonic, and power electronics, along with glass-to-metal and ceramic-to-metal feedthroughs,  hermetic connectors, and hermetic headers. The company also offers vacuum feedthroughs, battery end seals, TO headers,  and power packages to support fully integrated solutions. From design collaboration to production, Complete Hermetics delivers high-reliability hermetic packaging for the most demanding applications.

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Ceramic-to-Metal Seals for High-Temperature and High-Voltage Systems

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When Ceramic-to-Metal Seals Are Required

Ceramic-to-metal seals are selected when operating conditions exceed the temperature, voltage, or durability limits of glass-to-metal sealing technologies. These seals are engineered for extreme environments where high electrical isolation, thermal stability, and long-term reliability are essential. Applications involving high voltage, high temperature, vacuum, or radiation exposure often require ceramic sealing solutions to ensure performance and safety.

Advanced Ceramic Sealing Technology

Ceramic-to-metal seals are typically manufactured using high-purity alumina ceramics combined with metallization and brazing processes. The ceramic provides exceptional dielectric strength and thermal resistance, while the metal components ensure mechanical integrity and compatibility with system housings. This combination allows ceramic seals to maintain hermeticity under severe thermal cycling and electrical stress.

Mechanical and Electrical Performance

Unlike glass, ceramic materials maintain dimensional stability at very high temperatures and exhibit minimal deformation under load. This makes ceramic-to-metal seals ideal for applications where electrical insulation must remain stable over extended operating periods. Their resistance to arcing and electrical breakdown further enhances safety in high-voltage systems.

Extreme Conditions and Long-Term Stability

Ceramic-to-metal seals also perform exceptionally well in vacuum and radiation-sensitive environments due to their low outgassing and material purity. While these seals are more complex and time-intensive to manufacture than glass seals, their durability and performance justify their use in mission-critical systems where failure is unacceptable.

High-Performance Applications

Common applications include aerospace propulsion systems, medical imaging probes, vacuum chambers, semiconductor processing equipment, high-temperature sensors, and defense electronics. These environments demand sealing solutions that can withstand prolonged exposure to heat, pressure, and electrical stress without degradation.

 

Contact Complete Hermetics

Complete Hermetics designs and manufactures custom ceramic-to-metal seals and feedthroughs, along with glass-to-metal seals,  hermetic connectors, hermetic headers, and hermetically sealed packages for extreme environments. The company also supports specialized requirements with custom hermetic feedthroughs, power packages, and custom hermetic solutions tailored to demanding applications. By combining advanced materials with precision engineering, Complete Hermetics delivers sealing technologies customers can rely on.

Glass-to-Metal Seals for Precision Hermetic Technology

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How Glass-to-Metal Seals Work

Glass-to-metal seals are created by heating glass to a molten state and bonding it directly to metal under carefully controlled conditions. As the materials cool, the glass forms a strong, hermetic bond with the metal, creating an airtight and electrically insulating seal. This process allows electrical conductors to pass through metal housings without permitting moisture, gas, or contaminants to enter the sealed environment. Because of their proven reliability, glass-to-metal seals remain one of the most widely used hermetic sealing technologies across multiple industries.

Performance Advantages of Glass Sealing

One of the key advantages of glass-to-metal seals is their ability to maintain hermetic integrity under pressure changes, humidity exposure, and moderate temperature extremes. Glass provides excellent dielectric strength, corrosion resistance, and chemical stability, making it suitable for long-term use in harsh environments. Compared to epoxy or mechanical sealing methods, glass-to-metal seals offer significantly longer service life and more predictable performance over time.

Material Compatibility and Stability

Successful glass-to-metal sealing depends on matching the coefficient of thermal expansion (CTE) between the glass and metal components. Materials such as Kovar, Alloy 52, stainless steel, and copper-based alloys are commonly used to achieve this balance. When properly engineered, these seals tolerate thermal cycling and mechanical shock without cracking or leakage, making them suitable for both static and dynamic applications.

Manufacturing Precision and Repeatability

Glass-to-metal sealing requires precise control over glass composition, firing temperature, and cooling rates. This level of control ensures consistent quality and repeatability across production runs. As a result, glass-to-metal seals are ideal for both prototype development and high-volume manufacturing, allowing manufacturers to scale production without sacrificing reliability.

Common Applications

Glass-to-metal seals are widely used in glass-to-metal sealed lids, battery end seals, capacitor end seals, sensors, medical implants, and industrial electronics. They are also commonly found in automotive systems, pressure sensors, and energy storage devices where cost-effective hermetic performance is required.

 

Contact Complete Hermetics

Complete Hermetics is a custom manufacturer of hermetic sealing solutions, specializing in glass-to-metal seals, ceramic-to-metal seals, hermetic connectors, hermetic feedthroughs, hermetic headers, TO headers, vacuum feedthroughs, and battery end seals. The company designs and produces hermetically sealed components and custom hermetic assemblies for aerospace, defense, medical, energy, and telecom applications, delivering reliable performance in extreme environments from prototype development through full-scale production, backed by deep engineering expertise.

Hermetic Feedthroughs for Electrical and Vacuum Applications

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Purpose of Hermetic Feedthroughs

Hermetic feedthroughs allow electrical current or signals to pass into or out of sealed or vacuum systems while maintaining airtight integrity. Terms such as vacuum feedthroughs, electrical feedthroughs, glass feedthroughs, and ceramic feedthroughs are often used interchangeably, but all serve the same critical function.

Multi-Pin and Bulkhead Designs

Multi-pin hermetic feedthroughs and electrical bulkhead feedthroughs route multiple electrical connections through a single flange-mounted bulkhead. This reduces enclosure penetrations, improves system reliability, and simplifies system architecture. Contacts may be laser-welded or solder-in depending on electrical load and mechanical requirements.

Extreme-Environment Reliability

Hermetic feedthroughs are engineered to withstand high pressure, vacuum, vibration, and thermal extremes. Materials such as Kovar, stainless steel, titanium, and ceramic insulators provide durability and electrical isolation in harsh conditions.

Electrical Safety and Longevity

Feedthroughs also act as a safety barrier, preventing arcing and leakage in high-voltage systems. Proper spacing, insulation thickness, and material selection ensure long-term electrical continuity.

Industrial and Medical Uses

Applications include submersible pumps, downhole drilling instrumentation, exploratory equipment, implantable medical devices, and cryogenic surgical probes.

 

Contact Complete Hermetics

Complete Hermetics manufactures custom glass-to-metal and ceramic-to-metal hermetic feedthroughs, including bulkhead feedthroughs, multi-pin designs, and vacuum-rated configurations. The company also supplies hermetic connectors, headers, and sealed packages to support fully integrated solutions. From design to production, Complete Hermetics delivers reliable feedthrough technology for extreme environments.

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Hermetic Seals for High-Pressure and Harsh Environments

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What Are Hermetic Seals?

Hermetic seals are engineered to create a completely airtight barrier that prevents moisture, gas, and contaminants from entering sensitive electronic or mechanical systems. These seals are essential in applications where even microscopic leakage can cause performance degradation, safety issues, or catastrophic system failure. Industries such as aerospace, defense, medical devices, energy, and offshore drilling rely on hermetic sealing to protect mission-critical components operating in extreme conditions.

High-Pressure and Corrosion Resistance

Unlike conventional gaskets or epoxy-based sealing methods, hermetic seals prevent gas transmission through pressure boundaries. Glass-to-metal seals and ceramic-to-metal seals are the most widely used hermetic technologies because they offer excellent electrical insulation, corrosion resistance, and mechanical strength. These seals are specifically designed to withstand high pressure, vibration, thermal cycling, and chemically aggressive environments.

Materials and Sealing Technologies

Hermetic seals are manufactured using materials such as Kovar, stainless steel, Alloy 52, titanium, and aluminum, selected for controlled thermal expansion and long-term structural stability. Glass and ceramic sealing processes are precisely controlled to prevent cracking during temperature changes. These technologies ensure predictable performance across wide temperature ranges and long service lifetimes.

Lifecycle Reliability and Compliance

Hermetic seals also play a critical role in safety, regulatory compliance, and lifecycle cost reduction. Poor sealing can lead to corrosion, insulation breakdown, or electrical failure. Hermetic seals are commonly validated using helium leak detection, thermal shock testing, and pressure cycling to ensure long-term durability in regulated industries.

Applications Across Industries

Hermetic seals are used in medical implants, aerospace avionics, lithium battery assemblies, semiconductor housings, downhole drilling tools, and high-vacuum systems. They are also increasingly used in automotive and electric vehicle electronics, where moisture resistance and long operational life are essential.

Contact Complete Hermetics

Complete Hermetics is a custom manufacturer of glass-to-metal seals, ceramic-to-metal seals, hermetic connectors, hermetic feedthroughs, hermetic headers, and hermetically sealed packages engineered for extreme environments. In addition to precision sealing solutions, the company offers vacuum feedthroughs, battery end seals, TO headers,  and power packages for aerospace, defense, medical, energy, and telecom applications. From prototype development through full-scale production, Complete Hermetics partners closely with customers to deliver precision-engineered hermetic solutions with unmatched reliability.

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Vacuum Feedthroughs for High-Integrity Sealed Systems

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Why Vacuum Feedthroughs Are Essential

Vacuum feedthroughs allow electrical, optical, fluid, or mechanical transfer into or out of a sealed vacuum chamber without compromising the chamber’s integrity. They are crucial in semiconductor processing equipment, scientific research instruments, aerospace simulation chambers, and industrial high-temperature vacuum furnaces. Even the slightest leak can affect process quality, research accuracy, or equipment performance—making hermetic sealing absolutely essential.

Design Requirements for High-Vacuum Environments

Vacuum feedthroughs require materials that tolerate thermal expansion, pressure gradients, plasma exposure, outgassing, and radiation. Complete Hermetics engineers each feedthrough using precision glass-to-metal or ceramic-to-metal bonds calibrated to maintain ultra-low leak rates under severe operating conditions. These feedthroughs maintain performance from cryogenic to extreme high-temperature environments.

Configurations & Materials

Vacuum, electric, glass, and ceramic feedthroughs—often used interchangeably—serve the same core purpose: to route electrical current into or out of a hermetic or vacuum system while preventing any gas leakage. Complete Hermetics designs and manufactures custom glass-to-metal and ceramic-to-metal feedthroughs, including multi-pin and bulkhead hermetic feedthroughs that provide multiple electrical paths through a single flange. Available in laser-weld or solder-in styles, these feedthroughs deliver reliable performance in harsh environments. They are widely used in submersible pumps, downhole drilling tools, exploration instruments, implantable medical devices, and cryogenic surgical probes, where stable electrical continuity and long-term hermeticity are mission-critical.

Applications in High-Tech Sectors

Vacuum feedthroughs support:

  • Plasma etching & PVD/CVD semiconductor tools
  • Space environment simulation chambers
  • Ion beam accelerators & laboratory research equipment
  • Industrial furnaces & metallurgical processing
  • Aerospace test stands requiring high vacuum integrity

Testing & Verification

Every feedthrough undergoes low-helium-leak testing, electrical resistance measurement, thermal cycling, and long-duration vacuum compatibility validation. These processes guarantee reliability in systems where contamination or pressure loss cannot be tolerated.

Contact Complete Hermetics Today for Your Hermetic Solutions

Complete Hermetics provides high-performance vacuum feedthroughs and hermetic sealing technologies. From glass-to-metal or ceramic-to-metal configurations, each feedthrough is engineered with exacting precision to meet your application requirements.

Semiconductor Hermetic Packages for Precision Microelectronics

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Hermetic Packages Engineered for Demanding Environments

Complete Hermetics manufactures a full range of hermetic microwave, hybrid, power, photonic, and telecom packages designed for high-reliability applications in defense, aerospace, energy, medical, and advanced electronics industries. These hermetically sealed microelectronic enclosures are used in mission-critical environments where extreme temperature, vibration, pressure differentials, radiation, and chemical exposure can compromise sensitive semiconductor devices. Each package is engineered to protect internal circuitry, maintain signal integrity, and ensure decades of stable performance in harsh operating conditions.

Microwave and Hybrid Hermetic Packages

For RF, microwave, and millimeter-wave systems, Complete Hermetics produces precision hermetic microwave and hybrid packages compliant with MIL-883, MIL-PRF-38354, and JEDEC-9C standards. These packages incorporate customized feedthrough diameter combinations to meet complex impedance requirements, ensuring high-frequency stability and low-loss performance. Typical constructions include glass-to-metal seals, ceramic-to-metal seals, bent leads, and GPO connectors. Housing materials such as Kovar, stainless steels, CRS, Alloy 52/46, titanium, and aluminum provide controlled thermal expansion, structural robustness, and high-temperature endurance. Every unit undergoes stringent inspection including helium leak testing to ≤ ATM 1×10-8 cc/sec He, insulation resistance tests, and pin-pull tests to verify mechanical integrity.

High-Power Hermetic Packages for Thermal Demands

Complete Hermetics also manufactures hermetic power packages engineered to support high electrical loads and significant thermal dissipation. Many of these power enclosures utilize copper tungsten, copper molybdenum, and copper heat-spreading materials that effectively manage thermal expansion while allowing the enclosure to dissipate heat efficiently. These packages often incorporate glass feedthroughs, ceramic feedthroughs, and DIL/DIP packages with hermetic glass seals to ensure reliable electrical performance under high voltage and high current. Built to MIL-883/MIL-PRF-38354 specifications, each power package is tested for hermeticity, insulation resistance, pin strength, and dimensional accuracy to guarantee long-term durability in energy systems, aerospace modules, and industrial power equipment.

Photonic, Fiber-Optic, Telecom & Biomedical Hermetic Packages

For optical, telecom, and biomedical applications, Complete Hermetics produces hermetically sealed enclosures used in fiber-optic systems, photonic communication devices, biomedical diagnostics, and high-speed signal modules. These packages are built using durable materials including Kovar, stainless steels, CRS, Alloy 52/46, titanium, and aluminum, offering excellent thermal stability and corrosion resistance. Typical constructions include High-Temperature Co-Fired Ceramics (HTCC), multi-layer ceramic feedthroughs, glass-to-metal seals, and GPO or window-lens packages supporting optical coupling and high-frequency performance. With hermeticity levels of ≤ ATM 1×10-8 cc/sec He, these enclosures maintain optical clarity, electrical isolation, and mechanical precision even in harsh or sterilized environments. Complete Hermetics supports custom prototype development through full mass-production, ensuring tailored solutions for next-generation fiber-optic networks, photonic sensors, and biomedical instrumentation.

Commitment to Engineering Excellence

Across all package types—microwave, hybrid, power, photonic, telecom, and biomedical—Complete Hermetics engineering team works directly with customers to optimize design, material selection, sealing technologies, and testing protocols. Every hermetic package is built with strict process control and complete traceability, ensuring unmatched precision and customer satisfaction for high-performance semiconductor assemblies.

Contact Complete Hermetics:

Choose Complete Hermetics for ultra-reliable semiconductor hermetic packages and other advanced hermetic products engineered for advanced electronic systems.

Advanced Ceramic-to-Metal Seals and Feedthroughs for High-Temperature Performance

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Why Ceramic-to-Metal Seals Are Superior

Ceramic-to-metal seals provide unmatched insulation strength, temperature resistance, and structural durability—making them ideal for systems exposed to extreme conditions. Unlike glass seals, ceramics retain mechanical and electrical stability at temperatures exceeding 500°C and remain intact during rapid thermal cycling. These properties make CTM seals indispensable in aerospace propulsion, medical imaging equipment, semiconductor fabrication tools, and scientific instrumentation.

Material Properties & Bonding Precision

Complete Hermetics uses high-purity alumina ceramics, metalized with tungsten-molybdenum or moly-manganese layers, to enable strong brazed joints with Kovar, titanium, or stainless steel housings. This combination allows ceramic-to-metal seals to achieve extremely low leak rates and high dielectric breakdown voltage. Optional plating—gold, nickel, or silver—improves conductivity, corrosion resistance, and long-term material stability.

Applications Across High-Temperature Industries

Ceramic-to-metal seals are essential in:

  • High-voltage power systems
  • Vacuum and plasma processing equipment
  • RF amplifiers and radar transmitters
  • Aerospace ignition and propulsion assemblies
  • Nuclear diagnostic sensors
  • Industrial heating and furnace control systems

Engineering Collaboration & Testing

Complete Hermetics works closely with engineers to determine ceramic thickness, dielectric spacing, pin configurations, and mounting styles tailored to each application. Every component undergoes helium leak detection, thermal shock testing, vacuum cycling, and electrical qualification to ensure longevity and reliability.

Contact Complete Hermetics

Count on Complete Hermetics for robust, precision-engineered ceramic-to-metal seals and feedthroughs— your trusted partner for extreme-environment reliability.

Hermetically Sealed Packages for Harsh-Environment Electronics

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Purpose of Hermetic Packages

Hermetically sealed packages protect sensitive microelectronics against moisture, contaminants, chemical vapor, radiation, vacuum conditions, and extreme temperature cycles. Without hermetic protection, microchips, sensors, and laser components can suffer from corrosion, outgassing, electrical drift, or catastrophic failure. In aerospace, defense, semiconductor, and medical applications, hermetic packaging ensures long-term performance—even in environments where failure is not an option.

Types of Hermetic Packages Offered

Complete Hermetics manufactures hermetic microwave and hybrid packages for defense, aerospace, energy, and medical applications, delivering rugged microelectronic enclosures engineered for harsh environments where reliability is critical.

Complete Hermetics produces high-reliability hermetic power packages using copper tungsten, copper molybdenum, and copper materials to support high thermal expansion, efficient heat dissipation, and long-term hermetic performance through glass-to-metal or ceramic-to-metal seals.

Complete Hermetics manufactures hermetic packages for photonic, fiber-optic, telecom, and biomedical systems, enabling stable high-speed optical performance and providing fully customized solutions from prototype to production.

Precision Sealing & Manufacturing Process

Hermetic packages are sealed using laser welding, seam sealing, brazing, or glass-to-metal sealing depending on mechanical, thermal, and electrical requirements. Complete Hermetics ensures proper metallization, plating, internal routing, and thermal expansion matching to guarantee structural and environmental reliability. Internal cavities can be customized for chip alignment, lens coupling, fiber-optic feedthroughs, or high-speed signal pathways.

Applications in Demanding Industries

These packages are used in:

  • Satellites and deep-space communications
  • Radar & military electronics
  • Medical diagnostic technology
  • Semiconductor laser drivers
  • Harsh-environment sensor modules
  • High-reliability communication systems

Contact Complete Hermetics:

Choose Complete Hermetics for high-performance hermetically sealed packages engineered for extreme reliability and precision.