Hermetic Seals for High-Reliability Applications

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When it comes to ensuring absolute containment in harsh conditions, hermetic seals are indispensable. These highly specialized components are critical in a range of demanding industries—from aerospace and defense to medical and energy systems. As a leading hermetic seal manufacturer, Complete Hermetics delivers tailored solutions through its extensive line of hermetic products, including glass-to-metal seals, ceramic-to-metal seals, and advanced custom hermetic seals and feedthroughs.

Excellence in Glass-to-Metal Sealing

Glass-to-metal seals are widely used for their exceptional insulation properties, pressure resistance, and cost-efficiency. Using precisely engineered thermal expansion matching techniques, Complete Hermetics fabricates both compression and matched seals, capable of withstanding extreme temperatures, rapid pressure changes, and corrosive environments. These seals can achieve hermeticity rates up to 1 x 10⁻⁹ atm cc/sec He and insulation resistance exceeding 1 GΩ @ 100 VDC—ideal for electrical feedthroughs, RF, and microwave applications.

Complete Hermetics also offers a variety of plating options, including gold, silver, electroless nickel, and tin, to enhance corrosion resistance and bonding characteristics.

Advanced Ceramic-to-Metal Seals

For more rugged environments where glass-to-metal seals fall short, Complete Hermetics specializes in ceramic-to-metal seals. These are engineered for high-voltage, high-temperature, and high-pressure applications—such as vacuum chambers, aerospace modules, and diagnostic equipment. Though more labor-intensive, ceramic seals excel in endurance, offering extended reliability in temperatures up to 600°C when using our ceramic-doped glass innovation.

Customized Engineering and Sealing Innovation

Whether you need a hermetic solution for microelectronics, medical devices, or military systems, Complete Hermetics works directly with clients to design custom hermetic seals and feedthroughs that meet exact performance specifications. From titanium terminals for battery systems to high-reliability hermetic connectors, our engineering team delivers unmatched precision.

Engage Complete Hermetics for Your Hermetic Solutions

For expertly crafted hermetic products built to survive the toughest conditions, trust the expertise of Complete Hermetics. As a premier hermetic seal manufacturer, we’re ready to design the most reliable glass-to-metal and ceramic-to-metal seals on the market. Contact Complete Hermetics today to discuss your custom requirements and discover innovative solutions for your sealing challenges.

Best Electrical Feedthroughs for Hermetic Systems

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Understanding Hermetic Feedthroughs

In high-performance systems that demand absolute airtightness, electrical feedthroughs—also called vacuum feedthroughs, glass feedthroughs, or ceramic feedthroughs—play a vital role. These hermetic products are engineered to pass electrical signals or power through a hermetically sealed environment without compromising its integrity. Whether it’s in aerospace, defense, or advanced medical applications, the need for dependable, leak-proof electrical pathways is essential.

Why Hermeticity Matters

A hermetic feedthrough ensures that gas, moisture, or other contaminants cannot infiltrate sensitive equipment. This is critical in systems that operate under vacuum, extreme pressure, or highly corrosive environments. Without a proper seal, electronics can fail, leading to catastrophic system breakdowns. By using glass-to-metal or ceramic-to-metal feedthroughs, industries maintain stability and performance in even the harshest settings.

Custom Hermetic Feedthroughs for Specialized Applications

As a premier hermetic feedthrough manufacturer, Complete Hermetics provides custom hermetic feedthroughs built to exact specifications. Our team designs advanced solutions for applications including:

  • Submersible pump systems
  • Downhole oilfield instrumentation
  • Cryogenic and implantable medical devices
  • Satellite and aerospace controls

Our components are available in multi-pin configurations and can be adapted for bulkhead-style mounting. With options for laser welding or solder-in integration, we ensure a secure, vibration-resistant seal.

Engineered for Durability and High-Pressure Environments

Whether you need a single-channel connector or a complex multi-pin feedthrough, our hermetic products are built to endure. From cryogenic probes to military-grade equipment, each feedthrough undergoes rigorous testing for performance under high pressure, thermal shock, and corrosive conditions.

Partner with Complete Hermetics for Unmatched Reliability

If you need glass feedthroughs, ceramic components, or custom-engineered sealing systems, trust Complete Hermetics to deliver precision and quality. Our experience, innovation, and dedication to customer-specific solutions make us the go-to partner in the hermetic feedthrough market.

Explore our advanced hermetic solutions today. Contact Complete Hermetics for a consultation or request a custom quote. Experience the next generation of sealed performance.

MIL-SPEC Hermetic Connectors

Hermetic Connectors: Engineered Excellence for Extreme Environments

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In high-stakes industries such as aerospace, military, and advanced manufacturing, hermetic connectors are indispensable. These rugged, sealed interconnects maintain the integrity of mission-critical electronic systems by preventing the intrusion of gases, liquids, and moisture. As a key segment of hermetic products, these connectors are engineered for uncompromising performance under high pressure, elevated temperatures, and other severe operating conditions.

Custom Hermetic Connectors: Built for Precision

A leading hermetic connector manufacturer, Complete Hermetics offers a comprehensive range of custom hermetic connectors tailored to exact client specifications. Whether you require circle hermetic connectors or specialized variants for unique systems, our expertise in glass-to-metal and ceramic-to-metal sealing ensures long-term stability and protection. Materials such as Kovar, Stainless Steel, Titanium, and Aluminum are chosen for their superior sealing capability and compatibility with advanced applications, from avionics to semiconductor manufacturing.

Circle & Rectangular Hermetic Connectors for Versatility

For applications demanding round interconnects with compact yet robust construction, circle hermetic connectors are the preferred choice. These are available in solder-in or laser weld configurations, offering engineering teams flexibility in design and installation.

Rectangular hermetic connectors, including Sub D formats, are purpose-built for rugged defense, space, and industrial applications where space optimization and reliability are key. These rectangular models ensure secure integration into complex systems while delivering long-lasting hermetic protection.

MIL-Spec Hermetic Connectors: Trusted in Defense Systems

For the most demanding environments, MIL-Spec hermetic connectors—such as those adhering to MIL-DTL-38999 standards—are indispensable. Offering multiple shell sizes, coupling styles, and contact layouts, these connectors are designed for precision signal and power transmission in aerospace and military platforms. Complete Hermetics ensures full compliance with military specifications, making them a trusted partner in defense-grade connectivity.

Complete Hermetics: Your Hermetic Solutions Expert

When performance under pressure is non-negotiable, turn to Complete Hermetics. Our high-reliability hermetic products—from custom hermetic connectors to circle hermetic connectors  and advanced MIL-Spec hermetic connectors—deliver unmatched durability and sealing integrity. 

Contact Complete Hermetics today to find out how they can assist with your specific connector requirements and elevate the reliability of your critical equipment.

Top Hermetic Manufacturer Delivering Precision and Performance

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When it comes to reliable hermetic products, precision engineering and proven expertise are non-negotiable. As a top hermetic manufacturer, Complete Hermetics leads the industry with custom solutions for highly demanding environments. Specializing in glass-to-metal and ceramic-to-metal seals, the company develops advanced components tailored for aerospace, defense, medical devices, semiconductors, and energy systems.

Engineered for Performance in Extreme Environments

Whether you’re operating in vacuum, high-pressure, or high-temperature environments, Complete Hermetics offers components that ensure absolute sealing integrity. Their portfolio includes hermetic connectors, hermetic feedthroughs, and hermetic headers—all designed with precision to maintain signal integrity and eliminate the risk of leakage or contamination. These hermetic solutions are ideal for applications where failure is not an option.

Innovation in Hermetic Packaging and Integration

From hermetic packages to custom battery end seals and vacuum viewports, Complete Hermetics delivers advanced materials integration and performance. Their in-house expertise in brazing and soldering allows for tailored assemblies that meet rigorous industry and military specifications. Every component is engineered to maintain mechanical and electrical performance in the most demanding operating conditions.

Reach out to Complete Hermetics today to learn how our advanced solutions can improve the reliability and efficiency of your applications. We also offer expert customization in hermetic connectors, vacuum viewports, and hermetic headers designed to meet your precise requirements.

What is a Hermetic Package?

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In today’s high-stakes industries—where electronic components must withstand extreme environments—hermetic packaging solutions are essential. But what is a hermetic package? In essence, it’s a type of sealed enclosure designed to protect sensitive electronics from moisture, gases, dust, and other environmental hazards. Whether the need arises in aerospace, medical, or industrial settings, hermetic products deliver reliable performance and long-term durability.

The Purpose and Power of Hermetic Electronic Packages

Hermetic electronic packages provide airtight seals that preserve internal components and prevent environmental degradation. These packages are critical in applications like semiconductors, sensors, amplifiers, and modulators. Used widely in sectors such as offshore drilling, aerospace engineering, and advanced medical devices, hermetically sealed solutions ensure performance in high-pressure, high-vacuum, or high-frequency environments.

What sets these packages apart is their ability to maintain integrity for years. Seals produced by Complete Hermetics, for instance, are engineered for long-term durability, offering unmatched protection under the harshest conditions. This makes them ideal for telecom, microwave systems, fiber optics, and laser technology.

Custom Hermetic Packaging for Diverse Applications

Complete Hermetics specializes in designing and manufacturing custom hermetic packaging solutions tailored to each client’s specific needs. Whether you require flat packs, plug-in units, or plate configurations, their offerings meet the strictest MIL-883 standards for military-grade reliability.

From limited production runs of five units to full-scale manufacturing in the thousands, Complete Hermetics supports clients at every stage. Their comprehensive line of hermetic enclosures and packages is crafted for excellence, flexibility, and compliance across multiple industries.

Why Choose Complete Hermetics?

If you’re searching for hermetic products built to last and perform, Complete Hermetics is your trusted partner. With proven expertise in hermetic electronic packages, high-quality standards, and full customization capabilities, they provide the right solution for your critical application.

Get in touch with Complete Hermetics today to discover how their full line of hermetic packaging solutions can protect and enhance your electronic components.

Titanium headers

Why Are Battery End Seals Important?

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The Role of Hermetic Sealing in Battery Technology

In advanced battery systems, particularly lithium battery seals, the quality and precision of battery end seals are critical to performance and longevity. These seals serve as the frontline defense against environmental stressors such as temperature fluctuations, moisture, and electrochemical reactions. Without proper sealing, battery systems are at risk of failure, leading to reduced efficiency, safety hazards, and shortened service life.

Designed to Withstand Harsh Environments

Complete Hermetics specializes in hermetic products engineered for extreme conditions. Their custom glass-to-metal sealing technology provides exceptional resistance to corrosive agents, pressure changes, and electrical stress. Designed to perform from -40°C to over +150°C, these battery end feedthrough seals are essential for industries where reliability is non-negotiable—medical devices, communication infrastructure, weaponry, and automotive systems, to name a few.

Precision Materials and Rigorous Testing

Complete Hermetics offers tailored solutions using robust materials such as stainless steel, titanium, and alloy 52 for both the housing and internal pins. High-performance glass materials like Corning 9010 and TA23 are used to ensure superior sealing integrity. Each unit undergoes a 100% leak test with a sensitivity as low as 1×10⁻⁸ cc He/sec. Additional tests for electrical isolation and breakdown voltage are available upon request to guarantee optimal performance in demanding applications.

Partner with Complete Hermetics for Reliable Battery Seals

If your application depends on durable and high-performance battery end feedthrough seals, look no further than Complete Hermetics. With decades of experience in lithium battery seals and custom hermetic solutions, their team ensures precision engineering, rigorous testing, and fast turnaround times. Whether you’re building next-generation medical devices or mission-critical defense systems, Complete Hermetics delivers the reliability your innovations demand.

Contact Complete Hermetics today to discuss your battery sealing requirements and explore how their expertise in hermetic products can support your next breakthrough.

MIL-SPEC Hermetic Connectors

Everything You Need to Know About Hermetic Connectors: Top 20 Frequently Asked Questions

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Hermetic Connectors: Top 20 Frequently Asked Questions

Hermetic connectors are vital components in high-performance applications where airtight, moisture-resistant, and pressure-proof connections are critical. Whether you’re in aerospace, defense, medical, or industrial manufacturing, understanding these connectors can help you make better design decisions.

Here are the most frequently asked questions about hermetic connectors—answered clearly and concisely.

1. What is a hermetic connector?

A hermetic connector is an electrical connector that features a hermetically sealed interface to prevent the ingress of gases, liquids, and contaminants.

2. How do hermetic connectors work?

They work by using airtight materials—often glass-to-metal or ceramic-to-metal seals—that prevent any leakage across the barrier, maintaining the integrity of the system.

3. What is the difference between hermetic and non-hermetic connectors?

Non-hermetic connectors do not offer gas or moisture sealing, making hermetic connectors the go-to choice for critical, sealed environments.

4. What materials are used in hermetic connectors?

Typical materials include stainless steel, Inconel®, Kovar®, ceramics, and borosilicate glass for their thermal and chemical stability.

5. Are hermetic connectors waterproof or airtight?

Yes, they are designed to be both airtight and moisture-proof, ideal for high-pressure and vacuum environments.

6. What are hermetic connectors used for?

They are commonly used in aerospace, military, medical devices, oil & gas, vacuum chambers, and space technology.

7. Where are hermetic connectors commonly installed?

Applications include sensors, battery systems, vacuum systems, implantable devices, and satellite components.

8. How do you test a hermetic seal on a connector?

Common tests include helium leak detection and pressure testing to ensure airtight performance.

9. What are the temperature and pressure ratings for hermetic connectors?

Many hermetic connectors operate from -65°C to +200°C and withstand high pressures, depending on the design and materials used.

10. Can hermetic connectors be used in high-vacuum environments?

Yes, they are ideal for vacuum chambers, particle accelerators, and space applications due to their gas-tight sealing.

11. What industries use hermetic connectors?

Industries include:

  • Aerospace & Defense
  • Medical & Biomedical
  • Energy (Nuclear & Oil)
  • Industrial Automation
  • Telecommunications

12. Can I get custom hermetic connectors for my application?

Yes, many manufacturers such as Complete Hermetics offer custom hermetic connector solutions tailored to your voltage, current, pressure, and mounting needs.

13. What certifications are required for hermetic connectors in aerospace or medical devices?

MIL-SPEC (e.g., MIL-DTL-38999), ISO 9001, and other industry-specific certifications are often required for regulated environments.

14. What are MIL-SPEC hermetic connectors?

These are hermetic connectors designed and tested to meet U.S. military standards for reliability and performance.

15. Are there hermetic connectors for fiber optics or coaxial cables?

Yes, hermetic feedthroughs are available for fiber optics, RF, and coaxial connections.

16. What is a glass-to-metal hermetic seal?

A glass-to-metal seal uses glass fused to metal at high temperatures to create an airtight, corrosion-resistant seal.

17. What is a ceramic-to-metal seal in hermetic connectors?

Ceramic-to-metal seals are used when higher dielectric strength or temperature resistance is needed.

18. How do I choose the right hermetic connector for my project?

Consider:

  • Electrical specs
  • Environment (temperature, pressure)
  • Mounting configuration
  • Sealing method
  • Material compatibility

19. Can hermetic connectors be reused?

Some are reusable if undamaged, but many applications—especially in aerospace or medical—require new connectors for each use.

20. What are TO headers and how are they related to hermetic connectors?

TO (Transistor Outline) headers are hermetically sealed components used in packaging semiconductors and sensors—often integrated with hermetic connectors.

✅ Need Hermetic Connector Solutions You Can Trust?

Contact Complete Hermetics today to learn more about our custom hermetically-sealed connectors, circular hermetic connectors, rectangular hermetic connectors, and MIL-Spec hermetic connectors. We offer a wide range of standardized sizes and can tailor our designs to meet your most demanding requirements.

Vacuum Viewports

Best Custom Vacuum Viewports for Precision Optical Applications

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In industries where performance under extreme vacuum and temperature conditions is non-negotiable, vacuum windows—also known as hermetic windows, high vacuum viewports, or hermetically sealed viewports—are essential components. These specialized hermetic products serve as transparent barriers that maintain airtight seals while allowing optical, laser, or infrared transmission in vacuum systems.

Engineered for High Vacuum Precision

Custom vacuum viewports play a critical role in maintaining system integrity in high-stakes applications such as defense optics, space instrumentation, medical endoscopy, and laser designation. These components must meet demanding specifications for both optical clarity and hermetic sealing. Complete Hermetics stands at the forefront of this technology, offering precision-engineered high vacuum viewports that are manufactured to meet or exceed MIL-PRF-13830 standards.

Advanced Materials and Construction

To deliver reliability across harsh environments, Complete Hermetics provides hermetic windows in a variety of customizable materials:

  • Window Options: Sapphire, Fused Silica, Glass, Magnesium Fluoride, Zinc Selenide
  • Flange Materials: Stainless Steel (CF, NW), Kovar, Titanium, Aluminum

These materials are selected based on application-specific requirements such as thermal expansion, optical transmission range, and chemical resistance. All assemblies are leak-tested to a stringent <1×10⁻⁹ Atm·cc/sec HE rate and operate across an impressive thermal range from -100°C to 450°C.

Tailored to Your Specifications

From aerospace-grade sapphire windows to magnesium fluoride lenses for UV systems, each hermetically sealed viewport is custom-built in nearly any shape or size to integrate seamlessly with your platform. Whether you require circular, rectangular, or complex geometry, Complete Hermetics delivers solutions that ensure maximum performance and longevity.

Partner with Complete Hermetics

When precision matters most, trust Complete Hermetics for your custom vacuum viewports and hermetic product needs. Contact us today to discuss your application and experience the unmatched quality of our vacuum windows, laser-grade optics, and hermetically sealed viewports engineered to perform under pressure.

MIL-SPEC Hermetic Connectors

Hermetic Connectors for Rugged Environments: Precision You Can Rely On

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In demanding industries where absolute reliability is essential, hermetic connectors are a cornerstone of secure and stable interconnect technology. Engineered to perform under extreme pressures, high temperatures, and harsh environmental conditions, these hermetic products ensure the integrity of electronic systems by preventing the ingress of gases or moisture. Whether for aerospace, defense, or industrial use, custom hermetic circular connectors play a pivotal role in mission-critical applications.

Precision Engineering with Custom Hermetic Circular Connectors

Complete Hermetics specializes in manufacturing both glass-to-metal and ceramic-to-metal sealed connectors, delivering unmatched durability and performance. The company produces custom hermetic circular connectors using traditional materials like Stainless Steel and Kovar, along with lightweight alternatives such as Aluminum and Titanium. These materials are ideal for applications requiring reduced weight without sacrificing strength or seal integrity. Their circle hermetic connectors are available for solder-in and laser weld installations, providing flexibility across a range of engineering requirements.

Durability with Hermetic Rectangular Connectors

In addition to circular models, Complete Hermetics manufactures rectangular hermetic connectors designed for robust defense and industrial environments. These Sub D and other hermetically sealed rectangular formats meet the highest standards of durability and are engineered to withstand rugged operational settings. Like their circular counterparts, these are available for both solder and laser weld options, ensuring seamless integration into existing systems.

MIL-Spec Hermetic Connectors for Aerospace and Defense

The company’s most advanced offerings include MIL-Spec hermetic connectors, such as the highly trusted MIL-DTL-38999 circular connectors. These are a preferred solution for aerospace and military applications, offering nine shell sizes, multiple coupling methods, and a variety of contact arrangements. Complete Hermetics’ 38999 models meet full compliance with MIL-DTL-38999 standards, ensuring optimal performance in the field.

Partner with Complete Hermetics for High-Reliability Hermetic Solutions

When it comes to precision, durability, and absolute hermetic sealing, Complete Hermetics delivers superior results across all industries. Whether you need custom hermetic circular connectors, circle hermetic connectors, or rectangular hermetic connectors compliant with MIL-Spec, we’re ready to meet your exacting needs. Contact Complete Hermetics today for expertly engineered hermetic products that perform under pressure.

Hermetic Feedthroughs for Precision Applications Across Industries

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Understanding Hermetic Feedthroughs

Hermetic feedthroughs serve a vital role in protecting electrical systems by enabling the safe transmission of current through vacuum-sealed or high-pressure environments. These components are engineered to maintain airtight integrity while offering dependable conductivity across a sealed barrier. Whether referred to as vacuum feedthroughs, electric feedthroughs, or glass to metal feedthroughs, their function remains the same: to deliver performance without compromising the enclosure’s hermetic seal.

Versatile Hermetic Products for Complex Systems

Today’s industries—from aerospace to medicine—require highly reliable hermetic products to function under demanding conditions. At the heart of these solutions are custom hermetic feedthroughs, including multi pin hermetic feedthroughs and electrical bulkhead assemblies, all crafted to withstand extreme temperatures and pressures. These configurations often feature laser-welded or solder-in installations, ensuring leak-free performance in mission-critical applications such as submersible pumps, cryogenic medical devices, and downhole instrumentation.

Advanced Materials: Glass and Ceramic Feedthrough Technologies

Two of the most trusted designs in hermetic sealing are glass to metal feedthroughs and ceramic to metal feedthroughs. These technologies are selected based on the application’s temperature tolerance, thermal expansion compatibility, and dielectric strength. Each solution is engineered to provide optimal sealing and longevity, especially where electrical continuity and environmental isolation are non-negotiable.

Why Choose Complete Hermetics?

At Complete Hermetics, precision and customization are our top priorities. We specialize in designing and manufacturing custom hermetic feedthroughs tailored to meet the exact specifications of your system. Whether you require a single electric feedthrough or a high-density electrical bulkhead, we offer both prototyping and full-scale production to support diverse sectors.

Explore the full line of hermetic products at Complete Hermetics—your trusted partner in high-performance sealing solutions. From glass to metal feedthroughs to robust multi pin hermetic feedthroughs, we provide engineering excellence for every challenge. 

Contact Complete Hermetics today to discuss your next project or request a custom solution designed for your unique application.