Top 15 Frequently Asked Questions About Hermetic Seals and Feedthroughs

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Hermetic seals and feedthroughs are essential in industries that require airtight, corrosion-resistant, and high-temperature-capable components. From aerospace to medical devices, these components protect critical systems from environmental damage. Below are 15 top FAQs with concise answers to help you understand these vital technologies.

1. What is a hermetic seal?

A hermetic seal is an airtight and moisture-proof seal that prevents gas or fluid leakage between joined components.

2. What is a hermetic feedthrough?

A hermetic feedthrough allows electrical signals or power to pass through a sealed barrier without compromising the seal’s integrity.

3. What are glass-to-metal seals?

These glass-to-metal seals fuse molten glass with metal under controlled thermal expansion to create a strong, durable, and airtight bond.

4. What’s the difference between matched and compression seals?

Matched seals use materials with similar thermal expansion rates; compression seals use mismatched rates for higher strength and pressure resistance.

5. What applications use hermetic feedthroughs?

They are used in aerospace, military, medical implants, vacuum systems, and oil & gas instrumentation.

6. What materials are used in glass-to-metal seals?

Common materials include Kovar, stainless steel, Inconel, and alkali barium glass.

7. What’s the leak rate standard?

Complete Hermetics’ products meet or exceed 1×10⁻âč atm cc/sec He for superior hermeticity.

8. Are custom designs available?

Yes. Complete Hermetics offers fully customized solutions tailored to specific dimensions, materials, and electrical specs.

9. What are ceramic-to-metal seals used for?

For high-voltage, high-temperature, and corrosive environments that glass cannot withstand.

10. How do ceramic-doped glass seals differ?

They offer high thermal resistance (up to 600°C) at a lower cost than traditional ceramic-to-metal seals.

11. What plating options are available?

Platings include gold, silver, electroless nickel, and tin for corrosion resistance and solderability.

12. Can hermetic seals be used in medical devices?

Absolutely. Titanium terminals and headers are ideal for batteries, sensors, and diagnostic tools.

13. What electrical specs can be expected?

Typical insulation resistance exceeds 1 GΩ @ 100 VDC; dielectric strength depends on glass type.

14. What shapes and sizes are available?

Circular, rectangular, micro-D and custom headers are available across a wide range of standard and custom sizes.

15. Can feedthroughs handle high pressure?

Yes. Compression seals can withstand pressures up to 14,000 PSI, depending on design.

Why Choose Complete Hermetics?

Complete Hermetics is a leading custom manufacturer of glass-to-metal, ceramic-to-metal, and hermetic feedthroughs and seals. Our expert team designs hermetic connectors, headers, packages, and vacuum viewports to fit your exact requirements. Whether you’re in aerospace, defense, medical, or industrial sectors, we deliver high-performance, leak-proof solutions with precision and reliability.

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

Contact Complete Hermetics today – your partner in precision sealing solutions.

Top Hermetic Manufacturer for Precision Sealing Solutions

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When searching for the top hermetic manufacturer, industry leaders and engineers alike turn to Complete Hermetics—a company known for delivering high-performance, custom-built hermetic products designed for reliability in extreme conditions. From critical aerospace systems to sensitive medical devices, Complete Hermetics offers advanced solutions built to exacting standards.

Unmatched Expertise in Hermetic Sealing Technologies

At the heart of Complete Hermetics’ success is their mastery in developing both glass-to-metal seals and ceramic-to-metal seals. These precision-engineered solutions are critical for maintaining airtight protection in environments where performance, longevity, and safety cannot be compromised. Whether the application involves high pressure, fluctuating temperatures, or corrosive atmospheres, these hermetic seals ensure lasting integrity.

Comprehensive Hermetic Product Line

Complete Hermetics manufactures a full range of hermetic feedthroughs, hermetic connectors, and hermetic headers to meet stringent industry demands. These components are designed for mission-critical performance in sectors such as aerospace, defense, energy, communications, and semiconductors. The company’s hermetic packages are customized to maintain electrical performance and mechanical stability while preventing any leakage or contamination.

From small prototypes to large-scale assemblies, every part is meticulously tested for durability, electrical insulation, and leak tightness. The result? Industry-trusted components that consistently exceed expectations.

Advanced Manufacturing and Materials Integration

Beyond sealing components, Complete Hermetics offers in-house brazing and soldering to create seamless assemblies that support complex design needs. The company’s innovation in materials science, combined with tight quality control, allows it to deliver robust hermetic products such as vacuum viewports, battery end seals, and high-voltage hermetic feedthroughs tailored to your specifications.

Choose Complete Hermetics – Built for Your Application

Complete Hermetics is a custom manufacturer of glass-to-metal, ceramic-to-metal, hermetic seals, and hermetic feedthroughs. Our expert team works closely with clients to design and develop hermetic connectors, hermetic packages, hermetic headers, and more—ensuring every component meets your project’s unique requirements.

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📧 Email: info@completehermetics.com
🔗 Contact Form

Trust Complete Hermetics to deliver solutions that seal your success.

Hermetic Power Packages Built for Performance and Durability

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Hermetic power packages play a crucial role in protecting high-performance electronics from moisture, gas, and other environmental contaminants. Whether used in aerospace, military, medical, or industrial systems, these sealed enclosures ensure reliability and performance even in the most extreme conditions. Complete Hermetics leads the industry with precision-engineered hermetic packages designed to withstand thermal cycling, pressure changes, and corrosive environments.

Advanced Materials for Reliable Sealing

When developing hermetic power packages, material selection is key. Complete Hermetics manufactures enclosures using high thermal conductivity materials such as copper, tungsten-copper alloys, and other conductive metals to absorb and manage heat dissipation. These enclosures often integrate glass-to-metal seals or ceramic-to-metal seals, depending on thermal expansion, voltage isolation, and environmental demands. The result is a robust, long-lasting seal that maintains structural integrity in mission-critical applications.

Diverse Packaging Solutions for Specialized Applications

Complete Hermetics offers a wide range of hermetic microwave and hybrid packages, ideal for high-frequency applications in defense and communications. Our photonic and telecom package designs provide outstanding optical isolation and protection, making them perfect for fiber optics, laser diodes, and other light-based systems. These packages are engineered for signal clarity and noise suppression, essential in fast-paced communication environments.

High-Quality Hermetic Feedthroughs and Connectors

To support your power and signal transmission needs, Complete Hermetics designs custom hermetic feedthroughs that can withstand high voltage, temperature, and pressure variations. These components are made using glass-to-metal seals or ceramic-to-metal seals, ensuring long-term durability and superior insulation. Our solutions are ideal for medical devices, vacuum systems, aerospace equipment, and energy systems where performance is non-negotiable.

Complete Hermetics: Leaders in Hermetic Technology

Complete Hermetics is a custom manufacturer of glass-to-metal, ceramic-to-metal, hermetic seals, and hermetic feedthroughs. Our experienced engineering team works closely with clients to design and deliver hermetic connectors, hermetic packages, hermetic headers, vacuum viewports, and tailored solutions for your specific needs. Whether you’re in R&D or mass production, we’re here to ensure your project’s success.

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

Titanium headers

What Is a Battery Hermetic Header and Why Is It Essential?

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When it comes to powering mission-critical systems—from medical devices to aerospace technologies—ensuring a secure battery seal is non-negotiable. A battery hermetic header is a crucial component that protects sensitive internal components from external threats like moisture, pressure variations, and extreme temperatures. Whether you’re designing for high-voltage power packs or precision health devices, Complete Hermetics delivers unmatched expertise in creating dependable battery end seals that last.

The Gold Standard in Lithium Battery Protection

Complete Hermetics specializes in lithium battery seals, including precision-built lithium battery glass-to-metal sealed lids designed to perform in the harshest environments. These components withstand temperature fluctuations from -40°C to +150°C, resist electro-chemical corrosion, and ensure stability under high electrical loads. With a custom glass-to-metal sealing process, every seal is engineered for longevity and safety—critical for industries that cannot afford failure.

Built for Critical Industries

Our battery end feedthrough seals are trusted across a wide range of industries:

  • Medical and health equipment
  • Military and defense systems
  • Automotive power units
  • Sensor and monitoring devices
  • Satellite and aerospace communication

These headers and seals ensure operational integrity in the most extreme conditions—whether on land, in the air, or in the human body.

Rigorous Testing Ensures Leak-Free Performance

At Complete Hermetics, quality is non-negotiable. Each product undergoes 100% helium leak testing, with a minimum leak rate of 1×10⁻⁞ cc He/sec. Additional electrical testing—such as breakdown voltage and insulation resistance—can also be performed, guaranteeing performance in even the most demanding applications.

Your Custom Hermetic Solutions Partner

Complete Hermetics is your go-to source for custom glass-to-metal sealing, hermetic feedthroughs, and hermetic headers built to your exact specifications. Our engineers combine years of specialized experience with state-of-the-art technology to create components that meet both industry standards and your unique needs.

Let us bring your vision to life with precision-engineered solutions that ensure system integrity, no matter the environment.

Contact Complete Hermetics Today
📞 Phone: 714-265-1238
📧 Email: info@completehermetics.com
🔗 Contact Form: https://www.completehermetics.com/contact-us/

What Are Defense Hermetic Feedthroughs Used For?

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Hermetic feedthroughs in defense applications play a crucial role in ensuring secure, reliable electrical connections across pressurized or vacuum-sealed barriers. These precision-engineered components maintain airtight integrity while transmitting electrical signals or power, making them indispensable for high-performance environments like defense electronics, aerospace, naval systems, and other mission-critical applications. By preventing moisture, gases, and contaminants from breaching the sealed enclosure, hermetic seals preserve the integrity and longevity of sensitive electronics.

Custom Hermetic Feedthroughs Built for the Defense Industry

From radar systems and drones to underwater surveillance equipment, today’s military technologies demand highly robust, custom hermetic feedthroughs that perform under extreme conditions. Complete Hermetics specializes in designing tailored solutions—including multi-pin hermetic feedthroughs and electrical bulkhead hermetic feedthroughs—to fit specific environmental and performance needs.

Whether it’s enduring high pressures in submersible defense systems or maintaining electrical continuity in aircraft sensor arrays, our hermetic solutions are engineered to withstand temperature extremes, vibration, and corrosion. Laser-welded assemblies and vacuum-grade sealing ensure absolute reliability and zero leakage in any scenario.

Advanced Materials: Glass-to-Metal and Ceramic-to-Metal Seals

The right choice of materials is essential for optimal performance. At Complete Hermetics, we offer both glass-to-metal and ceramic-to-metal feedthroughs. Glass provides excellent hermeticity and thermal compatibility, while ceramic excels in high-voltage and high-frequency applications. Our engineers work closely with clients to choose the best configuration for durability, dielectric strength, and mechanical stability.

Complete Hermetics: Innovating Hermetic Technology

Complete Hermetics is a trusted custom manufacturer of glass-to-metal, ceramic-to-metal, hermetic seals, and hermetic feedthroughs. We bring decades of technical expertise to help you design and develop the perfect hermetic connectors, hermetic packages, hermetic headers, vacuum viewports, and more—each solution tailored to your application.

Whether your project requires prototyping or full-scale production, we deliver the quality, performance, and customization you need. Let us help you keep your systems protected and fully operational—anywhere in the world.

📞 Phone: 714-265-1238
📧 Email: info@completehermetics.com
🔗 Contact Form: https://www.completehermetics.com/contact-us/
🌐 Website: www.completehermetics.com

Explore solutions with Complete Hermetics—the leader in defense hermetic feedthroughs and sealing innovation.

Medical Hermetic Seals for Demanding Environments

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Medical hermetic seals play a critical role in protecting sensitive electronic and mechanical components across the healthcare industry. From surgical instruments and implantable devices to diagnostic systems, airtight integrity is vital to ensure safety, reliability, and long-term performance. Complete Hermetics delivers advanced, leak-tight solutions designed to meet the exacting standards of modern medical applications.

Why Hermetic Sealing for Medical Devices Matters

Hermetic sealing for medical systems ensures zero gas or moisture infiltration, preventing malfunctions that could compromise patient safety or diagnostic accuracy. These seals are especially vital in equipment operating under pressure or in harsh conditions, such as sterilization or bodily environments. Complete Hermetics offers decades of experience in sealing technology that meets the rigorous demands of the healthcare sector.

Glass-to-Metal and Ceramic-to-Metal Solutions

Complete Hermetics designs and manufactures a wide variety of glass-to-metal seals and feedthroughs and ceramic-to-metal seals and feedthroughs that deliver unmatched protection. These hermetic interfaces allow for safe and secure passage of power, signals, or fluids through the barrier while maintaining system integrity.

Whether your application requires electrical isolation, thermal resistance, or high-pressure tolerance, their seals are built for extreme precision. These components are used in life-saving devices including pacemakers, defibrillators, infusion pumps, and advanced imaging equipment.

The Value of Hermetic Connectors and Feedthroughs

From bulkhead penetrations to embedded modules, hermetic connectors and hermetic feedthrough solutions provide airtight performance while allowing vital connections to function without disruption. Each feedthrough is engineered to withstand medical sterilization processes, temperature shifts, and vibration—critical for mission-critical applications.

Trusted Hermetic Seals Manufacturer

As a leading hermetic seals manufacturer, Complete Hermetics stands out for its innovative engineering, U.S.-based manufacturing, and global service reach. With capabilities ranging from custom prototyping to full-scale production, they are a trusted partner to OEMs, hospitals, and medical device developers.

Contact Complete Hermetics Today

For robust, high-performance hermetic solutions in the medical industry, turn to Complete Hermetics. Their airtight designs, expert engineering, and commitment to quality make them your premier choice for critical sealing technology.

📧 Email: info@completehermetics.com
📞 Phone: 714-265-1238
🔗 Contact Form: https://www.completehermetics.com/contact-us/
🌐 Website: www.completehermetics.com

MIL-SPEC Hermetic Connectors

Aerospace Hermetic Connectors for High-Reliability Environments

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In aerospace and other mission-critical sectors, ensuring protection against environmental stress is non-negotiable. Aerospace hermetic connectors are engineered to provide absolute airtightness, blocking moisture, gas, and contaminants from sensitive electronic systems. These components are equipped with durable hermetic seals that uphold system integrity under pressure extremes, rapid altitude changes, and corrosive conditions.

Industries That Depend on Hermetic Technology

From satellites to submarines, a wide range of industries rely on hermetic feedthrough solutions for reliability and safety. In offshore drilling, custom hermetic connectors withstand intense humidity and salinity. In aerospace and defense, MIL-Spec hermetic connectors meet rigorous standards for shock, vibration, and temperature resilience. In the medical field, sealed systems enable sterilized tools and implantable devices to operate without contamination risk.

Connector Types and Material Options

Complete Hermetics manufactures an extensive selection of hermetic connectors to suit varying system needs. Their products include circle hermetic connectors and rectangular hermetic connectors, available in robust materials such as titanium, stainless steel, aluminum, and bronze. Sealing options include glass-to-metal and ceramic-to-metal technologies, with finishes like gold-plating, silver-plating, and tin-plating to enhance conductivity and corrosion resistance.

The Advantage of Custom Solutions

Precision matters—especially in environments where failure is costly. Custom hermetic connectors are designed for seamless integration and optimal performance, ensuring durability and airtightness in specialized applications. Customization also supports unique mechanical and electrical configurations that off-the-shelf connectors simply cannot accommodate.

Discover High-Performance Sealing from Complete Hermetics

Complete Hermetics is a trusted provider of engineered solutions, offering MIL-Spec hermetic connectors, hermetic feedthrough systems, and a wide range of custom sealing options tailored to meet strict industry requirements. With advanced manufacturing and rigorous testing, they ensure products exceed expectations in even the harshest conditions.

Explore the full range of precision-engineered hermetic solutions with Complete Hermetics today 

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📧 Email: info@completehermetics.com
🔗 Contact Form: https://www.completehermetics.com/contact-us/

Custom Hermetic Solutions for Mission-Critical Applications

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In high-stakes industries like aerospace, defense, semiconductors, and medical devices, custom hermetic solutions are not optional—they’re essential. The integrity of sensitive electronic systems depends on the performance of components that can resist moisture, gas, and extreme environmental conditions. That’s where hermetic seals and hermetic connectors come in—providing the airtight barrier necessary to ensure uninterrupted functionality in the harshest settings.

Engineered for Precision: Custom Hermetic Feedthroughs and Headers

Not all applications are the same, and neither are their sealing requirements. Complete Hermetics specializes in manufacturing hermetic feedthrough assemblies and hermetic headers designed for exacting specifications. Using materials such as Kovar, stainless steel, titanium, and aluminum, they offer glass-to-metal and ceramic-to-metal seals that meet rigorous performance standards. These materials not only deliver superior corrosion resistance and thermal durability but also maintain electrical isolation—an absolute must in high-reliability sectors.

Hermetic Connectors for Harsh Environments

From hermetic connectors that meet MIL-DTL-38999 specs to custom configurations in circular or rectangular formats, Complete Hermetics ensures connectivity without compromise. These connectors support a wide range of shell sizes and pin layouts, enabling seamless integration into aerospace control systems, satellite payloads, and advanced industrial automation setups. Each connector is leak-tested to meet or exceed helium leak standards, safeguarding your mission-critical assets against contamination and failure.

The Role of Hermetic Packages in System Longevity

Beyond connectors and headers, hermetic packages provide a complete enclosure solution for sensitive electronics. These airtight casings shield circuits and sensors from environmental hazards, including temperature fluctuations, vibration, and corrosive chemicals. Complete Hermetics crafts these packages with the same high standards that govern all of their hermetic product lines, ensuring consistent protection and performance.

Partner with Complete Hermetics Today

Whether you’re upgrading a defense system, designing advanced medical instrumentation, or building next-gen aerospace controls, trust Complete Hermetics for unmatched quality and customization in hermetic seals, hermetic feedthrough, hermetic connectors, hermetic packages, and hermetic headers. Their engineering team collaborates with you from concept to completion to deliver solutions that excel under pressure—literally.

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

The Role of Hermetic Feedthroughs in Enabling Reliable Sealed Systems

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In mission-critical applications—ranging from aerospace to medical devices—hermetic feedthroughs ensure that electrical signals pass through sealed barriers without compromising environmental integrity. These components protect sensitive electronics from gas, liquid, or pressure intrusions, maintaining functionality in extreme environments.

Engineered for Harsh Conditions

Designed for rugged conditions, hermetic products such as multi-pin hermetic feedthroughs and electrical bulkhead hermetic feedthroughs are built to endure high-pressure and high-temperature situations. In downhole instrumentation, submersible pumps, and cryogenic medical devices, these feedthroughs maintain electrical continuity even in the harshest conditions. Whether installed via soldering or laser welding, their durability supports continuous performance in deep drilling and implantable surgical systems.

The Science Behind Hermetic Sealing

The term “hermetic” refers to the state of being airtight—an essential property for devices operating in vacuum or pressure-regulated environments. Technologies like glass to metal seals and ceramic to metal seals prevent leakage and shield electronics from moisture, gas, or contamination. These seals are integral to hermetic connectors, which bridge power and signal paths without compromising the enclosure’s integrity.

Custom Solutions for Complex Designs

Every application is unique, which is why custom hermetic feedthroughs and hermetic headers are in high demand. Engineers require flexibility in design and performance, and Complete Hermetics delivers both. With a wide range of materials and configurations, they produce components tailored to your specifications—ensuring precision and reliability across all industries.

Choose Complete Hermetics for Sealing Excellence

As a premier hermetic seal manufacturer, Complete Hermetics combines advanced manufacturing, rigorous leak testing, and unmatched engineering expertise to deliver world-class hermetic products. Their glass to metal seals, ceramic to metal seals, and hermetic connectors are trusted by professionals in energy, medical, aerospace, and industrial sectors.

Partner with Complete Hermetics for custom-engineered solutions that protect your systems from the inside out. Contact Complete Hermetics today to start your next high-performance sealing project.

Titanium headers

Why Are Battery End Seals Critical for High-Performance Energy Systems?

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In today’s high-performance energy applications, maintaining reliability under extreme conditions is critical. This is where hermetic products come into play—especially in lithium battery systems. These systems depend on tight, durable glass to metal seals and ceramic to metal seals to protect against environmental threats like moisture, pressure changes, and chemical reactions. Without a robust seal, the risk of failure, leakage, or degradation increases dramatically, affecting both performance and safety.

Precision Engineering for Demanding Applications

Whether it’s for medical, military, aerospace, or automotive use, hermetic connectors and custom hermetic feedthroughs must deliver uncompromising performance. Leading the charge is Complete Hermetics, a trusted hermetic seal manufacturer known for their innovation and consistency. Their solutions are engineered to perform in temperature extremes from -40°C to +150°C and provide exceptional resistance to corrosive agents, high voltages, and physical stress.

Each hermetic header and feedthrough is customized using high-grade materials such as stainless steel, alloy 52, and titanium. Paired with top-performing glasses like Corning 9010 and TA23, these materials ensure maximum sealing integrity. Every unit is helium leak-tested to a sensitivity of 1×10⁻⁞ cc He/sec, with optional electrical isolation and breakdown voltage testing.

Applications That Demand Perfection

From implantable medical devices and missile guidance systems to EV batteries and aerospace satellites, industries worldwide rely on hermetic products to protect critical systems. Complete Hermetics doesn’t just manufacture seals—they engineer trust and longevity into each product. Their experience with custom hermetic feedthroughs and hermetic connectors allows for precise adaptation to complex design needs and stringent compliance standards.

Choose Complete Hermetics—Your Partner in Reliability

If your technology requires uncompromising protection, Complete Hermetics is your go-to hermetic seal manufacturer. With decades of experience and an unwavering commitment to quality, they deliver hermetic headers, battery end seals, and hermetic feedthroughs that meet the highest industry benchmarks.

Contact Complete Hermetics today to explore how their custom-engineered hermetic products can protect and power your most demanding applications. Let their expertise help your next innovation thrive under pressure.