TO Headers

High-Quality Hermetic Headers for Reliable Applications

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Hermetic headers are essential components in various industries, providing unmatched protection for sensitive electronic and mechanical systems. These innovative components, combined with hermetic terminals, ensure a reliable seal against environmental factors like moisture, gas, liquid, pressure, and extreme temperatures. Their robust design guarantees long-lasting performance in even the harshest conditions.

State-of-the-Art Hermetic Headers
Complete Hermetics leads the industry in designing and manufacturing top-tier hermetic headers. The company’s state-of-the-art capabilities and advanced process control ensure that every product meets stringent quality standards. Hermetic headers are critical for applications requiring absolute protection from environmental exposure, including aerospace, medical devices, telecommunications, and automotive systems.

Hermetic Terminals for Optimal Performance
Hermetic terminals are a vital part of hermetic headers, enabling secure electrical connections while maintaining the integrity of the seal. These terminals are engineered to resist corrosion and withstand varying pressures, ensuring exceptional durability. Complete Hermetics specializes in developing hermetic terminals tailored to specific requirements, offering unparalleled customization and precision.

TO Headers for Microelectronic Packaging
Among the most popular hermetic headers are transistor outline (TO) headers, widely utilized in microelectronic packaging. These headers are indispensable in transmitting and receiving optical signals in high-performance devices. TO headers are integral to both TOSA (transmitter optical subassemblies) and ROSA (receiver optical subassemblies), making them indispensable in fiber optic communications, data transmission, and other advanced applications. Complete Hermetics offers a comprehensive range of TO headers in various configurations, ensuring compatibility with diverse systems.

Why Choose Complete Hermetics?
Complete Hermetics is a trusted name in the field, offering high-reliability solutions that meet the exacting demands of modern industries. With a commitment to innovation and quality, the company delivers hermetic headers and terminals that excel in performance, longevity, and resistance to environmental stress.

For exceptional hermetic headers, multi-pin headers, hermetic terminals, and TO headers, trust Complete Hermetics. Their expertise and dedication make them the ultimate partner for applications requiring hermetically sealed protection.

Hermetic Feedthroughs: A Comprehensive Overview

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In the hermetic and vacuum-sealed industries, terms such as Vacuum Feedthrough, Electric Feedthrough, Glass-to-Metal Feedthrough, and Ceramic-to-Metal Feedthrough are often used interchangeably. Despite their varied names, these components share a critical function: facilitating the transmission of electrical currents while maintaining an airtight seal.

What Are Hermetic Feedthroughs?
Hermetic feedthroughs are essential in applications requiring strict isolation from environmental contaminants such as air, gas, or moisture. The term “hermetic” refers to the ability to create an airtight barrier, ensuring no gas or liquid leakage. In interconnect systems, hermetic seals and feedthroughs are engineered to prevent the passage of gases through pressure barriers. This technology is crucial in environments where maintaining a vacuum or specific atmospheric conditions is critical, such as aerospace, medical, and industrial applications.

Types of Hermetic Feedthroughs
Complete Hermetics specializes in designing and manufacturing a wide range of feedthroughs, including:

Applications and Durability
Hermetic feedthroughs are built to endure extreme environments. They are extensively used in submersible pumps, downhole drilling instrumentation, cryogenic medical devices, and exploratory implants. Their ability to withstand high pressures ensures consistent performance in critical applications such as surgical instruments and industrial machinery. The laser-welded and soldered designs enhance reliability and functionality across various demanding scenarios.

Complete Hermetics: Your Trusted Partner
Complete Hermetics leads the industry in designing and manufacturing custom hermetic feedthroughs. Their expertise includes prototyping and producing high-quality glass-to-metal and ceramic-to-metal feedthroughs. With a commitment to innovation and reliability, Complete Hermetics delivers solutions optimized for even the harshest conditions, ensuring seamless electrical performance and hermetic integrity.

Optimize your projects with Complete Hermetics‘ state-of-the-art feedthroughs—where precision meets durability.

Hermetically Sealed Connectors: Advanced Solutions for Extreme Environments

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Hermetically sealed connectors are essential components in applications where machinery and equipment are exposed to extreme conditions. From aerospace to medical industries, these specialized connectors ensure airtight protection, making them indispensable for sensitive electronic systems. Their robust design prevents the ingress of gases, moisture, and contaminants, safeguarding equipment functionality in harsh environments.

What Are Hermetically Sealed Connectors?

Hermetically sealed connectors are engineered to provide a secure, vacuum-tight seal between systems. They are commonly used in environments that experience extreme weather, fluctuating atmospheric pressure, and high altitudes. For instance, photographic and surveillance equipment on unmanned vehicles rely on hermetic seal products to maintain airtight integrity. These connectors are also critical in submarines and satellites, where they resist significant pressure differences while ensuring no moisture or gases compromise system performance.

Reliable Moisture and Gas Protection

One of the primary advantages of hermetic connectors is their ability to act as a robust barrier against moisture and gas penetration. When high-pressure differential barriers are necessary for electrical systems, poorly constructed seals can lead to malfunctions. Hermetically sealed connectors effectively mitigate these risks, providing long-term resistance to corrosion and ensuring system reliability. This is why industries like automotive, offshore drilling, and defense frequently use custom hermetic connectors tailored for their unique requirements.

Circular and Rectangular Connectors for Versatile Applications

Hermetically sealed connectors come in various configurations, including circular and rectangular designs, to accommodate different systems. Circular connectors are often preferred for their compact and durable build, making them ideal for aerospace and military applications. On the other hand, rectangular connectors offer versatility for larger-scale systems in manufacturing plants and laboratory equipment.

Custom Hermetic Connectors by Complete Hermetics

For high-performance hermetic sealing solutions, Complete Hermetics stands as a trusted provider. Their custom hermetic connectors are designed to meet specific mounting requirements, ensuring compatibility with diverse industrial applications. Whether you need connectors for vacuum chambers, submarines, offshore rigs, or medical devices, Complete Hermetics delivers precision-engineered solutions.

Choose Complete Hermetics for unparalleled expertise in hermetic seal products and connectors that protect critical systems from environmental challenges.

Titanium headers

Battery End Seals and Lithium Battery Glass-to-Metal Sealed Lid Solutions

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Battery end seals and lithium battery glass-to-metal sealed lids play a crucial role in ensuring the long-term reliability and safety of batteries, particularly in demanding applications. These components must withstand harsh environments while maintaining a hermetic seal to protect sensitive battery interiors from external factors. In this article, we’ll explore the key features of battery end seals and lithium battery glass-to-metal sealed lids, along with the superior solutions offered by Complete Hermetics.

Durability in Extreme Conditions

Battery end seals, especially those designed for lithium batteries, need to endure a wide range of harsh environmental conditions. Whether it’s extreme temperatures ranging from -40°C to over 150°C, electrochemical corrosion, humidity, or pressure variations, these seals must offer consistent performance. Additionally, the seals must resist the effects of high electrical currents, ensuring safety and longevity.

Lithium battery glass-to-metal sealed lids provide a robust solution for these challenges. They offer superior sealing properties, which are vital in applications such as medical devices, communication systems, automotive technologies, and military-grade weapon systems. These sealed lids ensure that the battery components remain isolated from harmful elements, preventing potential failures due to leaks or corrosion.

High-Performance Testing Standards

Complete Hermetics takes quality control seriously, conducting 100% leak testing on all battery end feedthrough seals. The company ensures a minimum leak rate of 1×10⁻⁸ cc He/sec, proving their commitment to producing highly reliable seals. If necessary, Complete Hermetics can also carry out electrical isolation tests and breakdown voltage assessments, ensuring that each product meets or exceeds industry standards.

Material Specifications and Customization

The materials used for battery end seals and lithium battery glass-to-metal sealed lids are vital for their durability and performance. Complete Hermetics utilizes high-quality body materials such as stainless steel, mild steel, titanium, and aluminum, while pin materials include alloy 52, molybdenum, and titanium. The glass materials, such as Corning 9010, TA23, and custom glass, are selected to meet specific application requirements.

Custom Sealing Solutions from Complete Hermetics

Complete Hermetics specializes in custom glass-to-metal sealing technologies. Their expertise ensures high-reliability solutions for battery end seals, particularly in lithium battery seal manufacturing. These battery end covers and capacitor lids are designed to withstand extreme environments such as high temperatures, electrochemical corrosion, and high electrical currents. For industries ranging from defense to medical technology, Complete Hermetics delivers dependable sealing solutions.

Expert in Hermetic Microwave and Hybrid Packages

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Complete Hermetics specializes in the manufacturing of hermetic microwave and hybrid packages for a range of industries, including defense, aerospace, energy, and medical fields. These microelectronic hermetic enclosures are critical in applications exposed to harsh environmental conditions. Our engineering team collaborates closely with clients to ensure optimal performance and customer satisfaction.

General Specifications

The hermetic packages produced by Complete Hermetics are designed to meet stringent standards. Our enclosures offer a hermeticity level of ≤ATM 1×10-8 cc/sec HE, ensuring high-level protection for sensitive electronics. The manufacturing process complies with MIL-883, MIL-PRF-38354, and JEDEC-9C standards, guaranteeing durability and reliability in even the most demanding environments.

Customizable Designs for Impedance Requirements

Complete Hermetics offers a variety of customized feedthrough diameter combinations to meet specific impedance requirements. Our packages are subject to rigorous testing, including insulation resistance tests and pin pulling tests, to ensure long-lasting performance.

High-Quality Housing Materials

We utilize only the best materials to manufacture our hermetic microwave and hybrid packages. These materials include Kovar, stainless steels, CRS, Alloy 52 and 46, titanium, and aluminum. Each material is chosen based on the specific needs of the application, ensuring the highest levels of performance and reliability.

Typical Package Configurations

Our packages are available in a variety of configurations to suit different applications. Options include glass-to-metal seals, ceramic-to-metal seals, bent leads, and GPO connectors. These versatile designs make our hermetic packages suitable for a wide range of electronic applications, from advanced military systems to cutting-edge medical devices.

By choosing Complete Hermetics, you are investing in robust, high-performance hermetic microwave packages that are engineered to last and meet the rigorous demands of today’s industries.

Custom Hermetic Connectors

Custom-Made Hermetic Seal Connectors

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When it comes to ensuring the integrity of sensitive equipment, custom-made hermetic seal connectors are essential. These connectors provide a reliable sealing solution that protects against the infiltration of oxygen, bacteria, and moisture, making them ideal for various industries such as aerospace, automotive, medical, and offshore drilling.

Versatile Applications

At Complete Hermetics, we specialize in designing custom hermetic connectors tailored to meet specific mounting requirements. Our connectors are perfect for a range of applications, including submarines, offshore oil rigs, vacuum chambers, laboratory equipment, and military aircraft. By filling the gaps left by conventional connector manufacturers, we ensure that our clients receive the most effective hermetic sealing solutions.

Precision Engineering for Every Need

Whether you’re seeking Mil-Spec hermetic connectors for military applications or custom designs for older or unique equipment, Complete Hermetics delivers. We manufacture connectors that adhere to standards such as MIL-DTL-38999, MIL-C-5015, MIL-C-26482, and MIL-C-26500, ensuring your specifications are met without compromise.

Lightweight Solutions

We also offer lightweight options for our hermetic connectors. Our titanium hermetic connectors are renowned for their high resistance to temperature while remaining lightweight. On the other hand, aluminum hermetic connectors provide an extremely light overall weight, making them suitable for low-temperature applications across military, aerospace, and commercial sectors.

Tailored Manufacturing Options

Complete Hermetics can produce both circular and rectangular connectors with glass-to-metal and ceramic-to-metal seals. Our customers have the flexibility to specify the number of contacts, sizes, and shell styles, ensuring they receive the perfect hermetically sealed connectors for their needs.

The Complete Hermetics Advantage

Located in Santa Ana, California, Complete Hermetics is a global leader in specialized hermetic connectors. We provide custom designs, modeling, and prototypes to meet the diverse needs of our clients. From small-scale manufacturing to mass production, we can accommodate projects of any size.

Complete Hermetics is your one-stop source for all hermetically-sealed connectors, including glass-sealed and ceramic-sealed options. Contact us today to discover more about our custom-made hermetic seal products and standardized sizes.

Hermetic Feedthroughs: Essential for Sealing and Electrical Connectivity

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Hermetic feedthroughs are vital components used to transmit electrical current through a hermetically sealed or vacuum system. The term “hermetic” refers to a state of being completely air or gas-tight, ensuring that no gases pass through pressure barriers. These specialized connectors play a critical role in industries requiring high-performance sealing and connectivity, such as aerospace, medical devices, and energy sectors.

Custom Hermetic Feedthroughs for Specialized Applications

Complete Hermetics specializes in designing and manufacturing custom hermetic feedthroughs to meet specific client requirements. Whether it’s a glass-to-metal or ceramic-to-metal design, these custom feedthroughs are tailored for applications that demand exacting specifications, including the most extreme environments. The customization process includes working with unique materials and advanced manufacturing techniques to ensure that each feedthrough offers the highest level of performance.

Our custom solutions have been used in various industries, from submersible pumps and downhole instrumentation to cryogenic medical probes. For complex or multi-functional systems, multi-pin hermetic feedthroughs are available to provide multiple connection points while maintaining an air-tight seal.

Electrical Bulkhead Hermetic Feedthroughs: Strength and Durability

Electrical bulkhead hermetic feedthroughs are another key product offered by Complete Hermetics. These feedthroughs provide multiple electrical connection points through a single bulkhead flange, optimizing both space and functionality. They are specifically designed to handle extreme conditions, such as high pressure in downhole drilling or the precision required for surgical instruments. By maintaining reliability and continuity of electrical power, these bulkhead feedthroughs ensure that critical systems continue to function even in the harshest environments.

Comprehensive Hermetic Solutions

Complete Hermetics is committed to providing the most advanced solutions for all hermetic sealing needs. The terms vacuum feedthrough, electrical feedthrough, glass feedthrough, or glass-to-metal feedthrough, and ceramic feedthrough or ceramic-to-metal feedthrough are often used interchangeably in the vacuum and hermetic sealing industries. At Complete Hermetics, we offer a broad range of feedthrough options, from standardized sizes to fully customized prototypes, ensuring your system operates smoothly and securely.

Contact Complete Hermetics today to learn more about our comprehensive product offerings and custom designs for your industry’s unique requirements.

MIL-SPEC Hermetic Connectors

Applications of Hermetic Connectors

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Hermetic connectors are used in a variety of applications where a high level of protection against environmental factors is required. Here are some common uses of hermetic connectors.

Vacuum and pressure systems

Hermetic connectors are used in vacuum and pressure systems, such as in the semiconductor industry, to create a seal that prevents air and other contaminants from entering the system.

Aerospace and defense

Hermetic connectors are used in aerospace and defense applications to protect electronics and other sensitive components from harsh environmental factors, such as high altitude, extreme temperatures, and electromagnetic interference.

Medical devices

Hermetic connectors are used in medical devices, such as pacemakers and hearing aids, to prevent bodily fluids and other contaminants from entering the device.

Oil and gas exploration

Hermetic connectors are used in the oil and gas industry to create a seal that prevents the ingress of harsh chemicals and other environmental factors.

Automotive applications

Hermetic connectors are used in automotive applications, such as airbag deployment systems, to protect electronics from heat, vibration, and other environmental factors.

Underwater applications

Hermetic connectors are used in underwater applications, such as submersibles and offshore oil rigs, to protect electronics from water and other corrosive substances.

Hermetic connectors are used in any application where protection against environmental factors is critical to the reliable operation of the system.

Circle Hermetic Connectors

Selling Points for Lithium Battery Seals

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Lithium battery seals employ the incredibly dynamic hermetic seal technology, which effectively makes the objects that are protected by them airtight. These seals can be applied to a large number of materials and are employed in a vast range of industries.

How Are Lithium Battery Seals Designed?

In the lithium battery design, the cells are all individually sealed and cannot leak. This benefits users because there is no restriction orientation of a lithium battery, which means that the battery can be installed upside down or on its side.

Hermetic connectors are a special class of sealed connectors that incorporate glass-to-metal or other highly-engineered sealing technology. Hermetic seal connectors are versatile and dynamic and are employed in a number of diverse applications, including submarines and satellites.

Whether you’re talking about hermetic seals and feedthroughs, battery seals, connectors or any other type of hermetic technology, this type of sealing is designed to ensure an absolute line of demarcation between the object and any other elements.

How Important Are Lithium Battery Seals?

Lithium battery seals prolong the life of your battery. Battery end seals also help to ensure that the battery doesn’t get too hot. The seals also prevent the emission of harmful gas and liquids. Contact Complete Hermetics today to get a quote or if you have any questions about our products and services.

The Lowdown on Lithium Battery Seals

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Lithium battery seals are critical components in many types of batteries. From medical equipment to weapons control systems, these batteries must serve as essential power sources. With durability, dependability and power output as important performance indicators, batteries’ seals should adequately support their functionality. In this short guide, you’ll learn about the advantages of battery seals constructed from lithium.

Benefits of Lithium Battery Seals

Battery end seals serve an important function: keeping a battery’s electrolyte and internal components inside its housing. A battery end seal ensures that its power cell stays reliable, functional and safe for ongoing use. Battery seals come in a wide range of materials:

  • Titanium alloys
  • Stainless steel
  • Aluminum
  • Steel alloys
  • Lithium

Complete Hermetics manufactures several lithium battery glass-to-metal sealed lid products. Glass-to-metal seals offer unique advantages. Their construction creates a reliable high-quality seal that withstands exposure to harsh conditions, including temperatures between -40°C and +150°C. They also resist humidity extremes, electrochemical corrosion, pressure variation and high-voltage electrical currents. Lithium seals offer excellent performance in all these areas, along with offering a longer shelf life.

Your Source for Lithium Battery Seals

Complete Hermetics custom crafts glass-to-metal and ceramic-to-metal seals, as well as hermetic seals and feedthroughs. Through engineering and manufacturing excellence, we deliver superior-grade products meeting strict quality standards. Request an online quote now or call us at (714) 265-1238.