Best Hermetic Product Manufacturer for Custom Solutions

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Why Manufacturer Expertise Matters

Choosing the best hermetic product manufacturer is critical for systems that operate in extreme environments. Hermetic components must meet exacting standards for leak integrity, electrical performance, and mechanical durability. Poor manufacturing quality can result in system failure, safety risks, and costly downtime.

Comprehensive Hermetic Product Portfolio

Complete Hermetics designs and manufactures a full range of custom hermetic products, including:

Custom Engineering and Prototyping

Unlike standard suppliers, Complete Hermetics focuses on custom hermetic solutions. The engineering team works closely with customers to develop prototypes, validate designs, and transition seamlessly into production. This collaborative approach minimizes risk and ensures optimal performance.

Advanced Manufacturing Capabilities

From glass-to-metal and ceramic-to-metal sealing to brazing and soldering, Complete Hermetics maintains strict process control and quality standards. The company supports both low-volume specialty projects and large-scale production programs.

Industries Served Worldwide

Hermetic products from Complete Hermetics support aerospace, defense, medical, semiconductor, energy, and industrial markets, where failure is not an option. Customers worldwide rely on the company’s expertise and consistency.

Partner with Complete Hermetics

As a trusted hermetic product manufacturer, Complete Hermetics delivers precision, reliability, and flexibility from design through production. Our engineering team collaborates closely with customers to develop custom sealing solutions that meet demanding electrical, mechanical, and environmental requirements. Using advanced materials, proven glass-to-metal and ceramic-to-metal technologies, and strict quality control, we ensure consistent performance in mission-critical, high-reliability applications across aerospace, medical, energy, and industrial markets.

📞 Phone: 714-265-1238
📧 Email: info@completehermetics.com
🔗 Contact Form

Choose Complete Hermetics for precision sealing solutions built to perform in critical environments.

Reliable Hermetic Vacuum Electrical Feedthroughs

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What Is a Vacuum Feedthrough?

Vacuum feedthroughs allow electrical current or signals to pass into or out of hermetic or vacuum systems while maintaining airtight integrity. The terms vacuum feedthrough, electric feedthrough, glass feedthrough, and ceramic feedthrough are often used interchangeably, but all serve the same fundamental purpose: preserving hermeticity across pressure boundaries.

Importance of Hermeticity in Electrical Systems

In electrical and vacuum systems, hermeticity prevents gas leakage that can disrupt pressure stability or damage sensitive electronics. Feedthroughs must maintain electrical insulation and mechanical strength under thermal cycling, vibration, and pressure variation.

Glass-to-Metal and Ceramic-to-Metal Options

Complete Hermetics manufactures both glass-to-metal feedthroughs and custom ceramic-to-metal feedthroughs. Glass-to-metal feedthroughs are cost-effective and reliable for moderate temperatures and pressures, while ceramic-to-metal feedthroughs support higher voltages, higher temperatures, and harsher environments.

Custom Feedthrough Configurations

Vacuum electrical feedthroughs can be customized with multi-pin layouts, bulkhead mounting, and laser-welded or solder-in contacts to meet specific electrical and mechanical requirements. Custom configurations allow engineers to optimize space, reduce leak paths, and improve system integration.

Applications in Critical Industries

Vacuum electrical feedthroughs are essential in aerospace, medical technology, semiconductor manufacturing, energy systems, and scientific research, where reliable electrical penetration of sealed environments is required.

Contact Complete Hermetics Today for Your Hermetic Capabilities

Complete Hermetics designs and manufactures vacuum feedthroughs, glass-to-metal feedthroughs,  ceramic-to-metal feedthroughs, hermetic connectors, and hermetic headers for extreme environments. In addition, the company provides battery end seals, TO headers, power packages and custom hermetic solutions to support complex systems. From engineering support to production, Complete Hermetics delivers dependable hermetic feedthrough technology worldwide.

MIL-SPEC Hermetic Connectors

Hermetic Seal Connectors for Reliable Electrical Interconnects

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Understanding Hermetic Seal Connectors

Hermetic seal connectors are engineered to provide dependable electrical connections while maintaining an air-tight and gas-tight seal across pressure boundaries. Their primary function is to prevent gases, moisture, and contaminants from entering sealed systems where environmental exposure could otherwise lead to corrosion, signal degradation, or mechanical failure. In hermetic systems, these connectors serve as a critical interface between internal electronics and external environments, ensuring long-term performance and protection.

Hermetic Sealing Across Pressure Boundaries

In hermetic interconnect applications, hermetic seal connectors prevent gas transmission through connector interfaces, even when penetrating pressurized bulkheads or sealed equipment housings. This capability is essential in systems exposed to pressure differentials, vibration, and temperature variation. Proper hermetic sealing preserves stable internal conditions and protects sensitive electronics from external contamination, making these connectors indispensable in high-reliability environments.

Design Options and Sealing Technologies

Complete Hermetics designs and manufactures hermetic seal connectors using advanced glass-to-metal and ceramic-to-metal sealing technologies. These connectors are available in both circular and rectangular configurations, with customizable contact counts, pin sizes, shell styles, and mounting options. Materials such as stainless steel, Kovar, titanium, and aluminum are carefully selected to meet mechanical strength, corrosion resistance, and environmental performance requirements.

Electrical Performance and Long-Term Reliability

In addition to acting as pressure barriers, hermetic seal connectors must maintain consistent electrical performance over extended service lifetimes. Stable contact resistance, insulation integrity, and precise mechanical alignment are essential to avoid intermittent faults or signal loss. Hermetic sealing minimizes oxidation and moisture ingress, reducing maintenance needs and significantly extending connector service life in demanding applications.

Industries and Applications

Hermetic seal connectors are widely used in aerospace systems, medical devices, offshore drilling equipment, industrial automation, energy infrastructure, and defense applications, where exposure to harsh environments is unavoidable and failure is not an option.

Why Choose Complete Hermetics

Complete Hermetics designs and manufactures hermetic seal connectors, hermetically sealed connectors, hermetic feedthroughs, and hermetic headers for demanding applications. In addition to connector solutions, the company offers vacuum feedthroughs, battery end seals, TO headers, and custom hermetic assemblies tailored to specific requirements. With deep engineering expertise and flexible manufacturing, Complete Hermetics delivers interconnect solutions built for reliability in extreme environments.

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High-Vacuum Feedthroughs for Critical Systems

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What Is a High-Vacuum Feedthrough?

High-vacuum feedthroughs are specialized hermetic components that allow electrical power or signals to pass through vacuum or pressure boundaries without leakage. In vacuum environments, even microscopic leaks can compromise system performance, contaminate sensitive processes, or cause equipment failure. High-vacuum feedthroughsare therefore essential in applications where stable pressure control and long-term reliability are required.

Hermeticity and Vacuum Integrity

Hermeticity refers to the condition of being completely air- or gas-tight. In vacuum systems, hermetic feedthroughs prevent gas migration through pressure barriers while maintaining electrical insulation and mechanical stability. These components are commonly validated using helium leak detection to ensure ultra-low leak rates suitable for high-vacuum and ultra-high-vacuum environments.

Glass-to-Metal and Ceramic-to-Metal Feedthroughs

Complete Hermetics designs and manufactures both glass-to-metal feedthroughs and ceramic-to-metal feedthroughs for high-vacuum applications. Glass-to-metal feedthroughs provide excellent electrical insulation and cost efficiency, while ceramic-to-metal feedthroughs are preferred for higher temperatures, higher voltages, and harsher operating conditions. Material selection is based on vacuum compatibility, thermal expansion matching, and electrical performance requirements.

Precision Engineering and Testing

High-vacuum feedthroughs must be manufactured with extremely tight tolerances to maintain vacuum stability over extended operating periods. Materials such as stainless steel, Kovar, titanium, and high-purity ceramics are selected for low outgassing and corrosion resistance. Rigorous inspection and testing ensure consistent electrical performance and long-term hermetic integrity.

Applications Across Industries

High-vacuum feedthroughs are widely used in semiconductor fabrication equipment, aerospace simulation chambers, medical imaging systems, research laboratories, and energy technologies where controlled environments are essential.

Engineering Expertise You Can Trust

Complete Hermetics manufactures high-vacuum feedthroughs, glass-to-metal feedthroughs,  ceramic-to-metal feedthroughs, hermetic connectors, and hermetically sealed packages engineered for extreme environments. In addition to vacuum solutions, the company provides battery end seals, hermetic headers, and power packages for aerospace, defense, medical, and industrial applications. From prototype development to production, Complete Hermetics delivers precision hermetic solutions with proven reliability.

Titanium headers

Battery End Seals for Lithium and High-Energy Systems

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Purpose of Battery End Seals

Battery end seals are critical hermetic components that protect internal battery elements from moisture, gas leakage, and contamination while allowing safe electrical connectivity. In lithium battery seals, maintaining hermetic integrity is essential to prevent performance degradation and safety hazards.

Glass-to-Metal Sealing for Batteries

Complete Hermetics utilizes advanced glass-to-metal sealing technologies proven to be highly reliable for battery end seals and capacitor lids. The molten glass bonds to metal housings and terminals, creating a robust hermetic and electrically insulating seal ideal for high-energy applications.

Performance in Harsh Conditions

Battery end seals are engineered to withstand extreme temperatures from –40°C to over +150°C, electro-chemical corrosion, humidity exposure, pressure variation, and high electrical currents. This durability ensures stable battery operation across long service lifetimes and demanding environments.

Testing and Quality Assurance

To ensure safety and performance, Complete Hermetics conducts 100% leak testing using helium mass spectrometry. The minimum leak rate is ≤ 1 × 10⁻⁸ cc He/sec. Additional testing such as high electrical isolation resistance and breakdown voltage testing can be performed as required.

Materials and Customization

Battery end seals are available in a wide range of materials:

  • Body materials: Stainless steel, mild steel, titanium, aluminum
  • Pin materials: Alloy 52, molybdenum, stainless steel, titanium
  • Glass materials: Corning 9010, 9013, TA23, Cabal 12, or custom glass formulations

Applications Across Industries

Battery end seals are used in medical equipment, communication systems, weapon systems, sensors, monitoring devices, and automotive electronics, where safety and reliability are critical.

Contact Complete Hermetics for Hermetic Solutions

Complete Hermetics specializes in battery end seals designed for maximum performance, safety, and durability. The company also manufactures  advanced battery feedthroughs, glass-to-metal lids, and other reliable hermetic components engineered to endure the most demanding conditions. Leveraging precision manufacturing and proven sealing technologies, every product delivers dependable, long-term reliability.

High-Pressure Hermetic Seals for Extreme Environments

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What Are High-Pressure Hermetic Seals?

High-pressure hermetic seals are designed to maintain a completely air-tight and gas-tight barrier in systems exposed to extreme pressure differentials. Hermeticity is defined as the state of being air or gas tight, and in interconnect applications, it refers to sealing technology that prevents gases from passing through pressure boundaries via connectors or feedthroughs. A classic hermetic application is a receptacle feedthrough penetrating a pressurized bulkhead or sealed equipment housing.

Why Pressure Integrity Matters

In high-pressure systems, even microscopic leaks can result in pressure loss, corrosion, electrical failure, or safety risks. Hermetic seals prevent gas migration while preserving electrical insulation and mechanical stability. This makes them essential in environments where reliability and safety are non-negotiable.

Custom Hermetic Sealing Solutions

Complete Hermetics specializes in custom hermetic products, including hermetically sealed connectors, hermetic headers, hermetic packages, hermetic seals, and hermetic feedthroughs. Every seal is engineered to meet specific pressure, temperature, and environmental requirements. Advanced modeling and prototyping capabilities allow precise optimization before production.

From Prototypes to Production

Whether customers require small-scale manufacturing for prototypes or mass production for thousands of components, Complete Hermetics supports the full lifecycle. The company works closely with customers to ensure exact specifications are met, regardless of application complexity.

Serving Global Industries

Located in Santa Ana, California, Complete Hermetics serves customers worldwide in aerospace, defense, energy, medical, offshore drilling, and industrial systems. High-pressure hermetic seals are widely used in pressurized vessels, downhole drilling tools, aerospace systems, and military equipment.

Contact Complete Hermetics Today

Complete Hermetics guarantees customer satisfaction through close collaboration, engineering expertise, and rigorous quality standards. Each hermetic seal is designed to perform reliably under extreme pressure and environmental stress.

Precision Hermetic Technology and Custom Hermetic Solutions

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Custom Hermetic Manufacturing Expertise

Precision hermetic technology requires deep materials knowledge, process control, and engineering collaboration. Complete Hermetics is a custom manufacturer of glass-to-metal seals, ceramic-to-metal seals, hermetic feedthroughs, and hermetic seals, supporting demanding applications across multiple industries.

Comprehensive Hermetic Product Portfolio

Complete Hermetics designs and manufactures a complete range of hermetic solutions, including:

Industries That Depend on Hermetic Precision

These products are vital to defense systems, medical technology, semiconductor equipment, energy infrastructure, and aerospace platforms, where failure is not an option.

From Concept to Production Scalability

Precision hermetic technology must support both early-stage development and long-term manufacturing scalability. Complete Hermetics works closely with customers during the concept phase to evaluate materials, sealing methods, and performance requirements before transitioning designs into repeatable production processes. This approach minimizes redesign risk and ensures consistency across production runs. Whether supporting low-volume prototypes, qualification builds, or full-scale manufacturing, precision process control enables reliable hermetic performance while meeting cost, schedule, and quality objectives for complex engineering programs.

Engineering, Prototyping & Manufacturing

Founded in 2002 and located in Santa Ana, California, Complete Hermetics is a wholly owned subsidiary of Aegis Technology Inc. The company offers extensive engineering support, rapid prototyping, and scalable manufacturing capabilities for both low-volume and production-scale programs.

Why Choose Complete Hermetics

Complete Hermetics delivers precision hermetic technology, including hermetic seals, feedthroughs, connectors, vacuum viewports, and hermetically sealed packages engineered for extreme environments. In addition, the company provides battery end seals, hermetic headers, power packages, and custom hermetic assemblies tailored to customer specifications. With advanced manufacturing and hands-on engineering collaboration, Complete Hermetics supports critical systems worldwide.

📞 Phone: 714-265-1238
📧 Email: info@completehermetics.com
🔗 Contact Form

Trust Complete Hermetics to deliver solutions that seal your success.

MIL-SPEC Hermetic Connectors

Hermetically Sealed Connectors for Aerospace and Medical Use

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What Are Hermetically Sealed Connectors?

Hermetically sealed connectors provide reliable electrical connections while preventing oxygen, moisture, bacteria, and contaminants from entering sealed systems. These connectors are designed for applications where conventional connectors fail due to corrosion, pressure changes, vibration, or temperature extremes.

A One-Stop Hermetic Connector Manufacturer

Complete Hermetics is a one-stop source for glass-sealed hermetic connectors and ceramic-sealed hermetic connectors, offering both electrically hermetic and vacuum-sealed connector solutions. Custom designs are available for virtually any mounting requirement, filling gaps left by conventional connector manufacturers.

MIL-Spec & Custom Connector Solutions

For military and aerospace applications, Complete Hermetics manufactures MIL-Spec hermetic connectors, including MIL-DTL-38999, MIL-C-5015, MIL-C-26482, and MIL-C-26500, as well as custom legacy replacements. Both circular and rectangular connectors are available with configurable contact counts, shell styles, and sealing technologies.

Lightweight Hermetic Connector Options

Weight matters. Titanium hermetic connectors provide exceptional strength-to-weight ratio and high-temperature resistance, while aluminum hermetic connectors offer ultra-lightweight solutions for low-temperature aerospace and military applications.

Environmental Protection and System Safety

Beyond electrical connectivity, hermetically sealed connectors play a vital role in protecting entire systems from environmental exposure. Moisture ingress, oxygen intrusion, and microbial contamination can quickly degrade sensitive electronics or compromise sterile environments in medical applications. Hermetic connectors create a sealed barrier that preserves internal conditions regardless of external pressure, humidity, or chemical exposure. This level of protection improves overall system safety, reduces maintenance requirements, and supports regulatory compliance in aerospace, medical, and defense industries where reliability and cleanliness standards are exceptionally strict.

Industries Served

Hermetically sealed connectors are used in submarines, offshore oil rigs, vacuum chambers, laboratory equipment, medical devices, and commercial and military aircraft, where reliability is critical.

Contact Complete Hermetics

Complete Hermetics manufactures hermetically sealed connectors, glass-to-metal seals, ceramic-to-metal seals, hermetic feedthroughs, hermetic headers, and vacuum-rated assemblies for extreme environments. The company also supports customers with custom connector designs, battery end seals, and power packages engineered to exact specifications. With flexible manufacturing and deep technical expertise, Complete Hermetics delivers hermetic connector solutions you can trust.

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Vacuum Feedthroughs for Hermetic Electrical Systems

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What Is a Vacuum Feedthrough?

Vacuum feedthroughs are essential components that allow electrical current or signals to pass into or out of a sealed or vacuum environment without compromising hermetic integrity. The terms Vacuum feedthrough, Electric Feedthrough, Glass Feedthrough, Glass-to-Metal Feedthrough, Ceramic Feedthrough, and Ceramic-to-Metal Feedthrough are often used interchangeably within the hermetic and vacuum industries. Regardless of terminology, the function remains the same: maintaining an airtight, gas-tight seal across a pressure boundary.

Why Hermeticity Matters

Hermeticity is defined as the condition of being completely air- or gas-tight. In interconnect applications, hermetic technology prevents gases, moisture, and contaminants from migrating through connectors or feedthroughs. Even microscopic leaks can disrupt system performance, contaminate sensitive processes, or cause long-term corrosion and electrical failure.

Glass-to-Metal vs. Ceramic-to-Metal Feedthroughs

Complete Hermetics designs and manufactures both glass-to-metal feedthroughs and custom ceramic-to-metal feedthroughs, allowing engineers to select the best solution based on temperature, voltage, pressure, and environmental demands. Glass-to-metal feedthroughs offer excellent electrical insulation and cost efficiency, while ceramic-to-metal feedthroughs provide superior performance in high-temperature, high-voltage, and harsh environments.

Electrical Performance and Long-Term Reliability

In addition to maintaining hermetic integrity, vacuum feedthroughs must provide stable electrical performance over long service lifetimes. Factors such as insulation resistance, dielectric strength, and contact stability are critical in high-vacuum and high-pressure environments. Poorly designed feedthroughs can lead to signal leakage, electrical noise, or insulation breakdown over time. By using proven glass-to-metal and ceramic-to-metal feedthrough technologies, systems benefit from consistent electrical isolation and reduced failure risk. This makes hermetic feedthroughs ideal for mission-critical systems where downtime, recalibration, or maintenance access is limited or impossible.

Custom Prototypes & Engineering Support

Every application is unique. Complete Hermetics specializes in custom prototypes for hermetic feedthroughs, working closely with customers to meet precise electrical, mechanical, and environmental specifications. Feedthroughs can be configured for laser-welded or solder-in installation, multi-pin layouts, and bulkhead mounting options.

Industries & Applications

Vacuum feedthrough are widely used in aerospace, defense, medical devices, semiconductor manufacturing, energy systems, and high-vacuum research equipment, where long-term reliability is non-negotiable.

Contact Complete Hermetics Today for Your Hermetic Capabilities

Complete Hermetics is a custom manufacturer of vacuum feedthroughs, glass-to-metal feedthroughs,  ceramic-to-metal feedthroughs, hermetic connectors, and hermetically sealed packages engineered for extreme environments. In addition to feedthrough solutions, the company provides battery end seals, hermetic headers, and power packages for mission-critical applications. From prototype to production, Complete Hermetics delivers precision hermetic solutions backed by deep engineering expertise.

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.