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

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The Advantage of Ceramic-to-Metal Technology

When environments exceed the limits of glass, ceramic-to-metal seals become the gold standard for thermal and electrical isolation. These seals are engineered to withstand extreme temperatures, voltages, and vacuum pressures without degradation—making them indispensable in aerospace propulsion, particle physics, and medical imaging systems.

High-Performance Applications

Ceramic-to-metal feedthroughs are used in high-voltage power transmission, RF systems, X-ray machines, and vacuum processing chambers. Their excellent dielectric strength ensures signal stability while maintaining full hermetic integrity.

Engineering and Design Excellence

Complete Hermetics produces custom ceramic-to-metal seals using alumina ceramics bonded to stainless steel, Kovar, or titanium through metallization and brazing. Each joint undergoes ultrasonic inspection, helium testing, and dimensional analysis to confirm long-term sealing reliability.

Benefits Over Traditional Glass Seals

Compared with glass, ceramics provide higher breakdown voltage, improved heat resistance, and lower leakage. This makes them ideal for applications exceeding 500 °C or operating under continuous voltage loads.

Collaborative Development Process

From prototype to production, Complete Hermetics works directly with customers to optimize designs for performance, manufacturability, and cost efficiency. Engineers can tailor electrode geometry, pin diameter, and insulation thickness to meet exact system needs.

Contact Complete Hermetics

Choose Complete Hermetics for high-reliability ceramic-to-metal seals and feedthroughs proven in extreme operating environments.

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Durable Hermetic Packages for Microwave and Power Systems

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Why Hermetic Packaging Matters

Hermetic packages protect microelectronic devices from contaminants, vibration, and pressure fluctuations. In high-performance industries such as defense, telecommunications, and energy, maintaining a moisture-free interior ensures stable performance and longer component life.

Comprehensive Hermetic Package Solutions

Complete Hermetics designs and manufactures hermetic microwave packages, hybrid packages, and power packages customized to each customer’s technical requirements. These packages isolate circuitry from environmental stress and provide strong mechanical support for chips, sensors, and optical components.

Microwave, Power, and Hybrid Designs

For microwave applications, Complete Hermetics provides low-loss packages capable of preserving high-frequency signal integrity. For high-power electronics, hermetic power packages use copper tungsten or copper molybdenum bases that effectively dissipate heat. Hybrid hermetic packages combine multiple components—such as sensors, amplifiers, or transistors—into one robust enclosure.

Photonic and Telecom Integration

In photonic and telecom industries, hermetic photonic packages prevent humidity and gas ingress that can distort or attenuate optical signals. The company’s telecom packages are used in fiber-optic networks, satellites, and medical imaging systems requiring low-loss data transfer and radiation resistance.

Precision Materials and Manufacturing

Using Kovar, aluminum, and titanium alloys, Complete Hermetics ensures low-CTE mismatch and excellent mechanical stability. Advanced metallization techniques allow for seamless glass-to-metal or ceramic-to-metal joints, maintaining high vacuum integrity even under thermal cycling.

Trust Complete Hermetics in Your Hermetic Packages

Whether you need microwave packages, hybrid packages, power packages, and photonic telecom packages, rely on Complete Hermetics to design, engineer, and produce high-performance enclosures built to endure the world’s most demanding environments.

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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.

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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 Packages for Electronics and Power Systems

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Why Hermetic Packages Matter

Hermetic packages are essential for protecting sensitive electronics from moisture, gases, and environmental stress. In aerospace, defense, energy, and medical industries, these packages ensure long-term reliability and performance in the harshest conditions.

Microwave and Hybrid Packages

Complete Hermetics designs and manufactures hermetic microwave and hybrid packages for advanced defense and aerospace systems. These enclosures are built to handle high-frequency performance while maintaining strict hermeticity, making them ideal for mission-critical applications.

Hermetic Power Packages

For high-power applications, Complete Hermetics produces hermetic power packages designed to handle significant thermal dissipation. Materials such as copper tungsten and copper-molybdenum are used to absorb and distribute heat effectively, ensuring system stability and durability under demanding operating conditions.

Photonic and Telecom Packages

In addition to defense and aerospace, Complete Hermetics manufactures hermetic photonic packages and telecom packages. These enclosures are widely used in fiber optic communication, biomedical devices, and high-speed telecom networks, where secure and airtight protection is required for sensitive components.

Custom Hermetic Packaging Solutions

From small prototype runs to full-scale production, Complete Hermetics collaborates with customers to design custom hermetic packages tailored to specific requirements. Their engineering expertise ensures each package delivers reliable performance in harsh environments.

Trust Complete Hermetics in Your Hermetic Packages

As a trusted hermetic package manufacturer, Complete Hermetics provides microwave packages, hybrid packages, power packages, and photonic telecom packages engineered to meet your specifications.

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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.

Hermetic Power Packages Built for Performance and Durability

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Hermetic power packages play a crucial role in protecting high-performance electronics from moisture, gas, and other environmental contaminants. Whether used in aerospace, military, medical, or industrial systems, these sealed enclosures ensure reliability and performance even in the most extreme conditions. Complete Hermetics leads the industry with precision-engineered hermetic packages designed to withstand thermal cycling, pressure changes, and corrosive environments.

Advanced Materials for Reliable Sealing

When developing hermetic power packages, material selection is key. Complete Hermetics manufactures enclosures using high thermal conductivity materials such as copper, tungsten-copper alloys, and other conductive metals to absorb and manage heat dissipation. These enclosures often integrate glass-to-metal seals or ceramic-to-metal seals, depending on thermal expansion, voltage isolation, and environmental demands. The result is a robust, long-lasting seal that maintains structural integrity in mission-critical applications.

Diverse Packaging Solutions for Specialized Applications

Complete Hermetics offers a wide range of hermetic microwave and hybrid packages, ideal for high-frequency applications in defense and communications. Our photonic and telecom package designs provide outstanding optical isolation and protection, making them perfect for fiber optics, laser diodes, and other light-based systems. These packages are engineered for signal clarity and noise suppression, essential in fast-paced communication environments.

High-Quality Hermetic Feedthroughs and Connectors

To support your power and signal transmission needs, Complete Hermetics designs custom hermetic feedthroughs that can withstand high voltage, temperature, and pressure variations. These components are made using glass-to-metal seals or ceramic-to-metal seals, ensuring long-term durability and superior insulation. Our solutions are ideal for medical devices, vacuum systems, aerospace equipment, and energy systems where performance is non-negotiable.

Complete Hermetics: Leaders in Hermetic Technology

Complete Hermetics is a custom manufacturer of glass-to-metal, ceramic-to-metal, hermetic seals, and hermetic feedthroughs. Our experienced engineering team works closely with clients to design and deliver hermetic connectors, hermetic packages, hermetic headers, vacuum viewports, and tailored solutions for your specific needs. Whether you’re in R&D or mass production, we’re here to ensure your project’s success.

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