Hermetic Headers for Reliable Electrical Interconnections

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What Are Hermetic Headers?

Hermetic headers are sealed electrical terminals designed to allow power or signal transmission into or out of a hermetically sealed device while preventing moisture, gas, or contaminants from entering. They serve as a critical interface between internal electronics and external connections, maintaining airtight integrity even in harsh operating environments. Hermetic headers are commonly used in batteries, sensors, medical devices, and microelectronic assemblies where reliability is essential.

TO Headers and Energy Applications

One of the most common forms of hermetic headers is the TO (Transistor Outline) header, widely used in microelectronics, sensors, and optoelectronic devices. In energy storage applications, battery hermetic headers, battery end seals and capacitor end seals provide safe electrical pathways while containing internal gases and preventing leakage. These headers are critical to battery safety, performance stability, and long service life.

Design and Manufacturing Precision

Hermetic headers must accommodate varying pin counts, spacing requirements, and electrical loads while maintaining leak-tight performance. Precision glass-to-metal or ceramic-to-metal sealing ensures each terminal remains electrically isolated and mechanically secure. Materials such as Kovar, stainless steel, Alloy 52, titanium, and aluminum are selected based on thermal expansion compatibility and corrosion resistance.

Compact Design with High Reliability

Hermetic headers enable compact device architectures without sacrificing environmental protection. Despite their small size, they must withstand vibration, thermal cycling, pressure changes, and mechanical stress. This makes them ideal for space-constrained applications such as implantable medical devices, aerospace sensors, and portable instrumentation.

Safety and Durability

By preventing moisture ingress and gas leakage, hermetic headers enhance safety and reliability in mission-critical systems. Properly engineered headers reduce the risk of short circuits, corrosion, and premature failure in demanding environments.

Contact Complete Hermetics

Complete Hermetics manufactures high-quality hermetic headers, including TO headers, battery end seals, along with glass-to-metal and ceramic-to-metal sealing solutions. The company also offers hermetic connectors, feedthroughs, vacuum viewports, and custom hermetic assemblies for aerospace, defense, medical, energy, and industrial applications. From prototype to production, Complete Hermetics delivers precision-engineered headers designed for long-term reliability.

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