Titanium headers

Battery End Seals for High-Reliability and Lithium Battery Applications

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Purpose of Battery End Seals

Battery end seals are critical hermetic components designed to protect internal battery elements from moisture, gas leakage, corrosion, and environmental exposure while allowing safe electrical connectivity. In high-energy battery systems—especially lithium battery seals—even minor leakage can result in performance degradation, safety hazards, or premature failure. Hermetic battery end seals ensure long-term containment and electrical stability in demanding operating environments.

Glass-to-Metal Sealing Technology for Batteries

Complete Hermetics utilizes advanced custom glass-to-metal sealing technologies that have proven highly reliable for battery end seal manufacturing. In this process, glass is heated to a controlled molten state and bonded to metallic housings and terminals, forming a robust, airtight, and electrically insulating seal. This technology is especially well suited for lithium battery end covers and capacitor lids, where consistent hermeticity and electrical isolation are mandatory.

Performance in Harsh Environments

Battery end seals manufactured by Complete Hermetics are engineered to withstand extreme environmental conditions, including wide temperature ranges from –40°C to over +150°C, electro-chemical corrosion, humidity exposure, pressure variation, and high electrical currents. These characteristics make them suitable for both portable and stationary energy systems operating in unpredictable or harsh conditions. The glass-to-metal interface provides excellent resistance to thermal cycling and long-term chemical exposure, ensuring stable performance throughout the battery’s lifecycle.

Testing, Inspection, and Reliability Assurance

To guarantee performance and safety, Complete Hermetics conducts 100% leak testing on battery end seals using helium mass spectrometry. The minimum guaranteed leak rate is ≤ 1 × 10⁻⁸ cc He/sec, ensuring exceptional hermetic integrity. When required, additional testing such as high electrical isolation resistance and dielectric breakdown voltage testing can be performed to meet customer or regulatory requirements. This rigorous inspection process supports use in mission-critical applications.

Material Specifications and Customization

Battery end seals are available in a wide range of material combinations to match application-specific requirements.
Body materials include stainless steel, mild steel, titanium, and aluminum, offering strength, corrosion resistance, and weight optimization.
Pin materials include Alloy 52, molybdenum, stainless steel, and titanium, selected for electrical performance and thermal compatibility.
Glass materials include Corning 9010, Corning 9013, TA23, Cabal 12, and custom glass formulations upon request.

Applications Across Industries

Hermetic battery end feedthrough seals are widely used in medical and healthcare equipment, communication systems, weapon systems, sensor and monitoring devices, automotive electronics, and energy storage systems where safety and reliability are paramount.

 

Contact Complete Hermetics Today for Your Reliable Hermetic Products

Complete Hermetics is a custom manufacturer of battery end seals, lithium battery glass-to-metal sealed lids, capacitor end seals, and other precision hermetic components engineered for extreme environments. In addition to battery sealing solutions, the company also offers custom ceramic-to-metal seals and feedthroughs, along with glass-to-metal seals,  hermetic connectors, hermetic headers, and hermetically sealed packages for aerospace, defense, medical, energy, and industrial applications. From prototype development through full-scale production, Complete Hermetics delivers reliable hermetic technologies backed by rigorous testing and deep engineering expertise.

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 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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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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MIL-SPEC Hermetic Connectors

Hermetic Connectors for Aerospace, Medical, and Defense Systems

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Why Hermetic Connectors Matter

Hermetic connectors provide sealed electrical interconnections while maintaining reliable electrical performance under extreme environmental conditions. They prevent moisture, gas, and particulate intrusion that can cause corrosion, insulation failure, or signal loss. These connectors are essential in aerospace, medical, defense, automotive, and industrial systems exposed to vibration, pressure changes, and temperature extremes.

MIL-Spec and Material Options

Many applications require MIL-Spec hermetic connectors, including circle connectors, and rectangular connectors. Materials such as titanium, stainless steel, Kovar, and aluminum are selected for strength, corrosion resistance, and lightweight performance. Titanium hermetic connectors are especially valuable in aerospace and medical systems where weight reduction and biocompatibility are critical.

Design Flexibility and Electrical Performance

Hermetic connectors can be configured for solder-in or laser-weld installation, high-density pin layouts, EMI shielding, and high-voltage or high-frequency operation. Glass-to-metal and ceramic-to-metal sealing technologies ensure long-term hermeticity even under mechanical shock and repeated thermal cycling.

System Integration and Longevity

Beyond environmental sealing, hermetic connectors support long-term system reliability by maintaining stable contact resistance and alignment. They reduce intermittent faults, minimize maintenance risk, and extend service life in systems where repair access is limited or impossible.

Mission-Critical Applications

Hermetic connectors are widely used in satellites, avionics, implantable medical devices, unmanned systems, and defense electronics.

Contact Complete Hermetics

Complete Hermetics is a custom manufacturer of hermetic connectors, glass-to-metal seals, ceramic-to-metal seals,  and hermetically sealed packages for demanding applications. The company also provides custom connector designs, battery end seals, TO headers,  and vacuum feedthrough solutions to meet specialized requirements. With precision engineering and flexible production, Complete Hermetics delivers hermetic interconnect solutions customers can trust.

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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.