Hermetic Seals and Feedthroughs for Extreme Environments

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Why Hermetic Seals Are Essential

Hermetic seals are critical to protecting sensitive electronics from gas, liquid, and pressure infiltration. Whether in aerospace flight control systems, industrial power assemblies, or medical equipment, the success of an electronic device often depends on the integrity of its hermetic sealing. When systems operate under high stress or environmental fluctuation, a small leak can lead to catastrophic failure.

Complete Hermetics Expertise

Complete Hermetics is a trusted hermetic seal manufacturer with decades of engineering experience. The company designs and fabricates both glass-to-metal and ceramic-to-metal feedthroughs, each tailored to meet precise mechanical, thermal, and electrical requirements. Every product undergoes helium leak detection, electrical insulation testing, and dimensional verification to ensure it exceeds global reliability standards. Their multidisciplinary team collaborates closely with clients to optimize performance, durability, and manufacturability for each application. With a commitment to innovation, Complete Hermetics continues to advance sealing technologies that meet the evolving needs of aerospace, medical, and defense industries.

Glass-to-Metal Seals and Applications

A glass-to-metal seal is formed when molten glass bonds tightly to metal under carefully controlled thermal expansion. The resulting structure creates a gas-tight joint ideal for devices exposed to temperature swings or humidity changes. Common applications include aviation sensors, industrial pumps, high-voltage connectors, and sealed relays. Compression and matched seals are both available depending on the intended use environment.

Ceramic-to-Metal Alternatives

When systems demand higher operating voltages or extreme temperature resistance, ceramic-to-metal seals provide superior dielectric strength and corrosion resistance. Complete Hermetics engineers these seals for medical scanners, power distribution modules, and vacuum enclosures used in aerospace and research.

Customization and Finishing Options

Materials such as stainless steel, Inconel, Kovar, and titanium are combined with custom plating—gold, nickel, or silver—for enhanced conductivity and solderability. Each configuration is designed in collaboration with the customer to meet functional, thermal, and geometric requirements.

Contact Complete Hermetics

For precision-engineered hermetic seals and feedthroughs that perform in the harshest conditions, trust Complete Hermetics —your global partner in dependable sealing solutions.

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Hermetic Headers and Multi-Pin Header Solutions

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Reliable Sealing for Signal and Power Transfer

Hermetic headers form the foundation of sealed interconnect systems by providing a gas-tight passage for electrical conductors. They prevent contamination and ensure uninterrupted signal and power flow in harsh operating environments, from satellites to medical implants. Their robust construction guarantees long-term reliability and protection against pressure, moisture, and temperature fluctuations.

Types of Hermetic Headers

Complete Hermetics manufactures multi-pin, single-pin, and TO headers, as well as customized terminals for specialized electronics. Each header is meticulously engineered to withstand temperature extremes, pressure changes, and corrosive conditions without leakage.

Precision Manufacturing and Materials

Headers are produced using stainless steel, Kovar, or titanium housings with glass-to-metal or ceramic-to-metal seals. Each assembly is inspected for alignment accuracy, leak rate, and dielectric integrity. Finishing options such as gold or nickel plating further enhance solderability and corrosion protection.

Applications and Performance

These headers are integral to medical sensors, defense electronics, power distribution units, and optoelectronic packages. Their superior hermeticity ensures system reliability in environments exposed to vacuum, heat, and vibration. They are engineered to maintain optimal electrical performance even under extreme mechanical and thermal stress.

Quality and Customization

Using state-of-the-art process control, Complete Hermetics guarantees consistent results from prototype to volume production. Clients can specify pin configuration, housing style, and electrical ratings to meet project-specific demands. Each unit undergoes rigorous testing to ensure compliance with the highest industry and military standards.

Contact Complete Hermetics

As a leading hermetic header manufacturer, Complete Hermetics supplies durable multi-pin headers, single-pin headers, and TO headers that meet the highest standards of performance and protection.

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Offshore Drilling Hermetic Solutions for Marine Equipment

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Protecting Systems Beneath the Surface

Offshore drilling hermetic solutions are essential for equipment exposed to saltwater, pressure fluctuations, and vibration. Subsea control modules, instrumentation, and power systems all rely on hermetic sealing to maintain performance and safety in one of Earth’s harshest environments.

Why Hermeticity Matters Offshore

At extreme ocean depths, water intrusion and corrosion can destroy unsealed electronics. Complete Hermetics designs glass-to-metal and ceramic-to-metal seals that prevent leaks even under thousands of PSI. Their seals resist electrochemical corrosion and ensure stable operation in deep-sea and high-salinity conditions.

Applications in Marine and Energy Industries

These hermetic components are used in offshore oil rigs, ROV sensors, subsea pumps, and oceanographic equipment. Their pressure-tested enclosures safeguard data acquisition and control systems used in deep-water exploration.

Engineering for Durability

Complete Hermetics utilizes titanium, Inconel, and stainless steel materials, chosen for their resistance to saltwater oxidation and mechanical fatigue. Each assembly undergoes hydrostatic and helium leak testing to confirm absolute reliability before deployment.

Custom Solutions for Every Project

Whether for shallow-water exploration or ultra-deep drilling, Complete Hermetics works directly with clients to create custom hermetic components optimized for subsea connectors, sensors, and power transmission.

Contact Complete Hermetics

Depend on Complete Hermetics for durable, corrosion-resistant offshore drilling hermetic solutions that protect your systems under the most demanding marine conditions.

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Reliable Electrical Feedthroughs for High-Voltage Systems

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Understanding Electrical Feedthroughs

Electrical feedthroughs are essential for transmitting power and signals through sealed or vacuum-tight walls while preventing any breach of hermeticity. They are widely used in scientific, aerospace, and industrial applications where reliable current flow must be maintained under vacuum, high voltage, or extreme temperature.

Design and Sealing Technology

Complete Hermetics uses advanced glass-to-metal and ceramic-to-metal bonding to produce leak-free, corrosion-resistant electrical feedthroughs. Each unit isolates conductors from metal housings, ensuring low resistance and high dielectric strength. The company’s process guarantees zero gas permeability and stability under mechanical stress.

Precision Engineering and Testing

Each feedthrough is designed with performance in mind. Options include single-pin and multi-pin configurations. All assemblies undergo vacuum testing, high-voltage dielectric checks, and pressure cycling to confirm absolute reliability before shipment.

Materials and Configurations

Complete Hermetics offers feedthroughs built from stainless steel, Inconel, or Kovar housings with ceramic insulators. Optional surface finishes—gold, nickel, or tin plating—enhance conductivity and solderability. These materials resist corrosion, heat, and wear, ensuring a long operational lifespan even in demanding conditions.

Industrial and Research Applications

  • Aerospace propulsion and flight-control systems
  • Semiconductor and vacuum-furnace environments
  • Particle accelerators and nuclear facilities
  • Medical imaging and diagnostic equipment

Contact Complete Hermetics

For dependable electrical feedthroughs that deliver precision, safety, and lasting performance, trust Complete Hermetics—your expert in high-integrity hermetic sealing.

Contact Info:

Contact Form: https://www.completehermetics.com/contact-us/ | Phone: 714-265-1238 | Email: info@completehermetics.com

Titanium headers

Lithium Battery Seals and Feedthroughs for Safety and Longevity

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Why Lithium Battery Sealing Is Critical

Lithium battery seals are crucial for preventing gas leaks, moisture ingress, and electrical shorting in energy-dense power systems. With the growth of electric vehicles, medical implants, and aerospace devices, the need for reliable sealing has never been greater. A well-engineered seal ensures long-term stability, safety, and optimal performance, protecting both the battery’s internal components and the end application it powers.

Advanced Glass-to-Metal Sealing Technology

Complete Hermetics produces battery end seals and glass-to-metal lids capable of withstanding extreme temperature swings from –40 °C to +150 °C. These seals resist electrochemical corrosion, vibration, and internal pressure fluctuations—ensuring both safety and performance over time.

Applications Across Industries

Battery end feedthrough seals from Complete Hermetics are used in:

  • Medical and healthcare equipment
  • Communication and monitoring systems
  • Electric and hybrid vehicles
  • Aerospace and defense power sources

Testing and Quality Assurance

Each seal undergoes a leak-rate test of 1 × 10⁻⁸ cc He/sec and insulation checks to ensure air-tight integrity. Optional plating in nickel, gold, or tin enhances corrosion resistance and solderability.

Engineering Support and Customization

The engineering team collaborates with clients to design custom geometries, feedthrough pin counts, and housing materials to meet specific energy-density and thermal-expansion needs. This collaborative approach ensures every hermetic connector is optimized for performance, reliability, and seamless integration into the client’s system.

Contact Complete Hermetics Today

For reliable lithium battery seals, battery feedthroughs, and glass-to-metal lids built for safety, performance, and endurance, parther with Complete Hermetics today.

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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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MIL-SPEC Hermetic Connectors

High-Performance Hermetic Connectors for Harsh Environments

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Why Hermetic Connectors Matter

Hermetic connectors are vital in protecting electrical and electronic systems from gases, liquids, and extreme temperature swings. Used in aerospace, energy, medical, and industrial equipment, they guarantee reliability when standard connectors would fail. Their sealed construction maintains full electrical functionality in high-pressure and high-vibration environments.

Complete Hermetics Connector Solutions

Complete Hermetics manufactures both glass-sealed and ceramic-sealed hermetic connectors, available in circle, rectangular, and MIL-Spec configurations. Whether for signal integrity, high-power transfer, or data communication, each connector is custom-built to maintain absolute hermeticity and electrical stability.

Engineered Materials for Strength and Weight Reduction

Durability and efficiency meet in every design. Traditional Kovar and stainless-steel connectors are ideal for high-temperature and structural applications, while aluminum and titanium hermetic connectors provide lightweight alternatives for aerospace and defense systems. Each connector undergoes rigorous testing for vibration resistance, thermal shock, and leakage.

MIL-Spec and Custom Options

Complete Hermetics meets or exceeds MIL-DTL-38999, MIL-C-5015, and MIL-C-26482 standards, producing MIL-Spec hermetic connectors trusted by military and aerospace manufacturers worldwide. For legacy or obsolete systems, the company also provides custom-engineered connectors tailored to match older designs while meeting modern performance demands.

Applications Include:

  • Aerospace avionics and propulsion systems
  • Medical diagnostic and monitoring equipment
  • Automotive control and sensing systems
  • Power and communications systems in extreme conditions

Contact Complete Hermetics

Choose Complete Hermetics for precision-built hermetic connectors engineered for long-term reliability under heat, pressure, and vibration.

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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.

Contact Info:

Contact Form: https://www.completehermetics.com/contact-us/ | Phone: 714-265-1238 | Email: info@completehermetics.com

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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