Hermetic Headers for Reliable Sealing Solutions

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What Are Hermetic Headers?

Hermetic headers are essential components for protecting electronics from moisture, gases, and extreme environmental conditions. They provide airtight sealing for applications that require resistance to temperature, vacuum, corrosion, and pressure variations.

Types of Hermetic Headers

Complete Hermetics manufactures a full range of hermetic headers, including:

Each header is engineered with precision to deliver maximum reliability across industries such as aerospace, defense, automotive, and medical devices.

Complete Hermetics Header Solutions

With advanced glass-to-metal and ceramic-to-metal sealing technologies, Complete Hermetics ensures every header meets strict performance standards. Their state-of-the-art manufacturing and process controls guarantee hermetic integrity, electrical performance, and corrosion resistance.

Applications include:

  • Power and signal transfer in harsh environments
  • High-voltage and vacuum systems
  • Optoelectronic devices and photonics packaging
  • Medical sensors and implantable devices

Reliability in Harsh Environments

By using durable materials such as stainless steel, Kovar, titanium, and ceramics, Complete Hermetics designs hermetic headers that maintain sealing even under extreme vibration, pressure, or temperature fluctuations. Customers can choose from standard or fully custom header designs.

Contact Complete Hermetics

As a trusted leader in hermetic headers, Complete Hermetics delivers multi-pin headers, single-pin headers, and TO headers with unmatched reliability. Every product is built to meet your exact specifications for performance and durability.

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Titanium headers

Lithium Battery Seals for High Reliability

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Why Lithium Battery Seals Are Critical

In modern technology, lithium battery seals play a crucial role in ensuring durability, safety, and long-term performance. From consumer electronics to aerospace and defense, these seals provide airtight protection that prevents moisture, gas, and chemical intrusion into sensitive power systems.

Battery End Seals and Glass-to-Metal Lids

Complete Hermetics specializes in battery end seals and lithium battery glass-to-metal sealed lids that can withstand the toughest environments. These components are designed for applications requiring maximum reliability, including:

  • Medical devices and health equipment
  • Communication and sensor systems
  • Automotive and electric vehicles
  • Aerospace and defense weapon systems

Performance Under Extreme Conditions

Lithium battery feedthrough seals are engineered to perform in environments with:

  • Temperature ranges from -40°C to +150°C
  • High pressure and vibration exposure
  • Electrochemical corrosion and humidity sensitivity
  • High electrical currents and voltage fluctuations

These features make them indispensable for industries that depend on consistent and safe energy supply.

Complete Hermetics Battery Solutions

With expertise in glass-to-metal sealing technologies, Complete Hermetics manufactures lithium battery seals and battery end feedthrough seals that meet the most demanding requirements. Every component undergoes leak testing and quality inspection to guarantee hermeticity.

By providing both small runs and large production capabilities, Complete Hermetics delivers flexible solutions for customers across industries.

Contact Complete Hermetics Today

As a trusted battery end seal manufacturer, Complete Hermetics produces reliable lithium battery seals, battery end feedthrough seals, and custom glass-to-metal sealed lids for critical applications.

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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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Ceramic-to-Metal Seals and Feedthroughs for Harsh Conditions

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Why Choose Ceramic-to-Metal Seals

Ceramic-to-metal seals provide exceptional performance in environments where high temperatures, high voltages, and extreme pressures are present. Compared to glass-to-metal alternatives, ceramic-to-metal feedthroughs are designed for applications that demand the highest durability and reliability.

Applications of Ceramic-to-Metal Feedthroughs

Industries that depend on ceramic-to-metal feedthroughs include:

  • Aerospace and defense systems
  • High-voltage and power equipment
  • Vacuum and semiconductor chambers
  • Medical devices and diagnostic systems

These seals ensure maximum protection against leaks, electrical breakdown, and environmental damage.

Advantages of Ceramic-to-Metal Technology

Unlike glass seals, ceramic-to-metal hermetic seals can withstand harsher environments for longer periods. Their resistance to electrical stress and thermal shock makes them ideal for applications where standard sealing methods may fail. While production is more labor-intensive, the results deliver unmatched strength and durability.

Complete Hermetics Ceramic-to-Metal Solutions

Complete Hermetics specializes in custom ceramic-to-metal seals and feedthroughs, offering solutions built to precise customer specifications. Their expertise in engineering and materials ensures each product performs reliably, even in the most demanding conditions.

Applications include high vacuum feedthroughs, electrical feedthroughs, and advanced power or defense-related systems where precision sealing is critical.

Contact Complete Hermetics

As a trusted hermetic seal manufacturer, Complete Hermetics provides custom ceramic-to-metal seals and feedthroughs for industries worldwide. Our team will design and manufacture components to meet your exact requirements for performance and reliability.

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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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MIL-SPEC Hermetic Connectors

Hermetically Sealed Connectors for Extreme Applications

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Why Use Hermetically Sealed Connectors?

Hermetically sealed connectors protect sensitive electronics from oxygen, moisture, and contaminants. These connectors are vital in aerospace, automotive, medical, offshore drilling, and military industries where reliable sealing ensures uninterrupted performance.

Complete Hermetics Connector Solutions

Complete Hermetics offers a full range of hermetic connectors, including:

Whether you need lightweight options for aerospace, rugged solutions for submarines, or specialized designs for laboratory equipment, Complete Hermetics provides dependable performance.

Military and Industry Standards

For defense and aerospace systems, Complete Hermetics manufactures MIL-Spec hermetic connectors that meet rigorous requirements, such as:

  • MIL-DTL-38999
  • MIL-C-5015
  • MIL-C-26482
  • MIL-C-26500

Customizations include circular or rectangular connectors, number and size of contacts, shell style, and sealing technology.

Lightweight Materials for Modern Demands

With advanced materials like titanium and aluminum, c delivers hermetic connectors that reduce weight without sacrificing strength. Titanium withstands extreme temperatures, while aluminum offers cost-effective lightweight performance—ideal for military, aerospace, and commercial use.

Contact Complete Hermetics

As a trusted hermetic connector manufacturer, Complete Hermetics supplies hermetically sealed connectors tailored to your exact requirements. From MIL-Spec to custom designs, we engineer connectors that perform under the harshest conditions.

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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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MIL-SPEC Hermetic Connectors

Aerospace Hermetic Connectors for Reliable Sealing

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Why Aerospace Needs Hermetic Connectors

In the aerospace industry, reliability is critical. Aerospace hermetic connectors protect sensitive systems from gas, moisture, and harsh environments. These connectors provide hermetic seals that prevent failures in high-altitude and space applications.

Types of Hermetic Connectors

Complete Hermetics manufactures a wide range of custom hermetic connectors:

With both glass-to-metal and ceramic-to-metal sealing, these connectors ensure durability under extreme conditions.

Lightweight Materials for Performance

While traditional Kovar and stainless steel are widely used, Complete Hermetics also offers lightweight titanium and aluminum hermetic connectors. These options reduce system weight while maintaining strength—an advantage for aerospace systems where every gram matters.

Built for Extreme Environments

Whether in spacecraft, satellites, or aircraft, hermetic connectors must withstand vibration, pressure changes, and extreme temperatures. Complete Hermetics designs connectors to perform consistently in the toughest conditions.

Contact Complete Hermetics

Complete Hermetics is a trusted hermetic connector manufacturer, offering aerospace hermetic connectors, circle hermetic connectors, rectangular hermetic connectors, and MIL-spec hermetic connectors tailored to your needs.

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Hermetic Headers for Extreme Environments: Precision Meets Protection

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In mission-critical industries where failure is not an option, hermetic headers play a pivotal role in ensuring the performance and longevity of sensitive electronic systems. From aerospace to medical devices, these components are engineered to create airtight seals that block out moisture, gas, and pressure variations—guaranteeing reliability even in the harshest operating environments.

Engineered with Glass-to-Metal and Ceramic-to-Metal Seals

At the core of every high-performance hermetic header lies advanced sealing technology. Glass-to-metal and ceramic-to-metal seals offer superior electrical insulation, mechanical strength, and environmental resistance. Whether embedded in a satellite module, surgical implant, or defense sensor, these headers maintain internal integrity when exposed to extreme temperature swings, corrosive elements, or high altitudes.

Custom Multi-Pin and TO Headers for Complex Assemblies

When high-density signal or power transmission is required across sealed barriers, multi-pin hermetic headers provide the optimal solution. These are critical in advanced systems such as pacemakers, avionics, and communication devices. For high-frequency or optoelectronic uses, TO headers (Transistor Outline headers) are designed to support TOSA/ROSA modules, delivering precision connectivity while managing thermal constraints.

Hermetic Connectors and Feedthroughs for Ultimate Reliability

In underwater, vacuum, or space applications, hermetic connectors and feedthroughs act as the protective bridge between sealed environments and critical electronics. Available in both standard and custom configurations, they provide long-term seal integrity and ensure continuous operation across demanding industrial and scientific settings.

Partner with Complete Hermetics for Custom Hermetic Solutions

Complete Hermetics is your trusted U.S.-based manufacturer of hermetic seals, offering custom-engineered hermetic headers, hermetic connectors, feedthroughs, and vacuum viewports. Our expert team combines decades of knowledge in glass-to-metal and ceramic-to-metal sealing technologies to design and manufacture components tailored to your exact performance specifications.

🔹 Contact Complete Hermetics Today
📞 Phone: 714-265-1238
📧 Email: info@completehermetics.com
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Experience unmatched reliability, precision, and protection with Complete Hermetics—engineered for excellence.