Custom Hermetic Connectors for Extreme Environments

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MIL-SPEC Hermetic Connectors

Why Custom Hermetic Connectors Are Needed

Custom hermetic connectors offer airtight electrical interface solutions for systems operating under vibration, shock, extreme temperatures, pressure differentials, or chemical exposure. When standard connectors cannot meet the demands of aerospace vehicles, medical implants, industrial machinery, or defense platforms, custom hermetic connectors provide the durability, stability, and leak-proof performance required for uninterrupted operation.

Glass-to-Metal and Ceramic-to-Metal Sealed Connectors

Complete Hermetics produces connectors utilizing both glass-to-metal (GTM) and ceramic-to-metal (CTM) sealing technologies. GTM connectors offer excellent cost efficiency and strong bonding, while CTM connectors provide exceptional dielectric strength, temperature tolerance, and long-term structural integrity. The sealing method chosen depends on the required voltage, frequency, biological exposure, and operational environment.

Custom Styles, Geometries & Materials

Customers can specify circular, rectangular, bulkhead, inline, high-voltage, RF, or multi-contact connector designs. Materials like Kovar, stainless steel, aluminum, and titanium enable optimal performance across aerospace, medical, and industrial environments. Plating options—gold, nickel, or tin—improve conductivity, solderability, and corrosion resistance.

Industry Applications

Custom hermetic connectors are vital in:

  • Deep-space avionics and propulsion control
  • Implantable medical devices and surgical robotics
  • Harsh-environment test systems
  • High-temperature turbine monitoring
  • Subsea digital communication systems
  • Military-grade power modules & sensors

Engineering Support & Performance Verification

Each connector undergoes rigorous testing including helium leak detection, thermal cycling, high-voltage dielectric testing, vibration testing, insulation resistance, and mechanical durability assessment. Complete Hermetics collaborates with engineers to ensure every custom connector meets mechanical, electrical, and environmental requirements.

Contact Complete Hermetics

Choose Complete Hermetics for precision-built, fully customizable hermetic connectors engineered to exceed performance expectations.