Ceramic to Metal Brazing - Soldering

Ceramic to Metal Brazing Solutions for Hermetic Sealing Applications

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What is Ceramic to Metal Brazing?

Ceramic to Metal Brazing is a specialized joining technique that bonds ceramic components to metal parts, offering unmatched durability, biocompatibility, and resistance to extreme environments. Widely used in medical devices, laser assemblies, microwave tubes, and electrical feedthroughs, this method provides high joint strength for vacuum, high voltage, and high-pressure conditions. With growing demand in aerospace, defense, and biomedical sectors, this technology is becoming essential for advanced engineering systems.

Key Materials & Brazing Processes

Brazing ceramics like Polycrystalline Alumina (94%-99%), Sapphire, BeO, Si3N4, AlN, and ZrO2 to metals such as Kovar, Molybdenum, Titanium, Inconel, and Nickel Alloys requires precision. Common brazing methods include:

  • Vacuum Brazing
  • Active Metal Brazing
  • Hydrogen Brazing
  • Reactive Air Brazing

The choice of braze alloy—gold, silver, copper or their alloys—depends on application-specific requirements for conductivity, strength, and corrosion resistance. Pre-metallization through Mo/Mn thick film or sputtering thin film enhances bond quality and reliability.

Custom Hermetic Products for High-Reliability Systems

When creating mission-critical systems, ensuring a hermetic seal is paramount. Solutions such as hermetic connectors, glass to metal seals, ceramic to metal seals, and hermetic headers are all vital components in devices requiring long-term performance in harsh environments. Whether for implantable medical devices or satellite communication modules, these hermetic products protect sensitive electronics from moisture, pressure shifts, and chemical exposure.

Complete Hermetics: Your Trusted Hermetic Seal Manufacturer

As a leading hermetic seal manufacturer, Complete Hermetics offers extensive expertise in custom hermetic feedthroughs, ceramic to metal brazing, and full-cycle prototype development. Their capabilities span modeling and simulation, fixture design, and stress/failure analysis, ensuring dependable solutions for even the most demanding applications. All assemblies are meticulously tested for leak rates as low as 1×10⁻⁸ cc He/sec and meet stringent reliability standards.

Get Started with Complete Hermetics Today

Partner with Complete Hermetics for your next advanced assembly project. Whether you’re designing for medical, military, or industrial applications, their engineering team is ready to help.

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

How Hermetic Headers Safeguard Critical Electronics Across Industries

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In environments where failure is not an option—such as aerospace, medical, and defense systems—hermetic products play a crucial role in protecting sensitive electronics. Among them, hermetic headers stand out for their unmatched ability to shield internal components from moisture, corrosive gases, extreme temperatures, and pressure fluctuations. Trusted across mission-critical applications, these components are the silent protectors of performance and safety.

Precision-Engineered Hermetic Headers

At the heart of many electronic assemblies lies the glass to metal seal or ceramic to metal seal, ensuring airtight integrity. These technologies, central to the design of hermetic headers, prevent environmental ingress while supporting high electrical insulation and mechanical strength. From satellite modules to surgical implants, these headers maintain operational stability under the harshest conditions.

Multi Pin Headers: Designed for Demanding Interfaces

Custom hermetic feedthroughs like multi pin headers offer seamless signal transfer between sealed environments. These components are key for data, power, and signal continuity while preserving the integrity of the system. In scenarios where life or mission success depends on reliability, such as avionics or pacemakers, these headers are indispensable.

TO Headers for Optoelectronic Precision

TO headers, or Transistor Outline headers, are optimized for optical and high-frequency applications. Often integrated into TOSA and ROSA assemblies, they enable superior performance in communication systems. Every TO header from Complete Hermetics is carefully tailored to meet your exact specifications—ensuring reliability in both space-limited and heat-sensitive environments.

Hermetic Connectors: Dependable Sealing for Complex Systems

Whether used in subsea installations or vacuum chambers, hermetic connectors provide robust sealed interfaces between different electronic units. These connectors, available in standard or custom hermetic feedthroughs, protect against system failure by maintaining perfect seals under dynamic pressure and thermal stress.

Partner with Complete Hermetics for Hermetic Excellence

As a premier hermetic seal manufacturer, Complete Hermetics delivers cutting-edge solutions, including hermetic headers, hermetic connectors, and custom-engineered seals. Our proven expertise in glass to metal seals and ceramic to metal seals ensures that your technology remains protected from the elements. Explore our complete line of hermetic products today and experience the precision and performance only Complete Hermetics can deliver.

Contact Complete Hermetics today to explore our full line of hermetic products. 

 

Vacuum Viewports

What Makes Custom Hermetic Viewports Essential for High-Tech Applications?

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In advanced fields such as defense, space, medical endoscopy, and laser optics, the need for precision-engineered hermetic products is non-negotiable. One critical component that supports these high-stakes operations is the hermetically sealed viewport—also known as a vacuum window, hermetic window, or vacuum viewport. These terms are often used interchangeably across industries that demand airtight performance and enduring material integrity under extreme conditions.

Why Hermetic Viewports Are Crucial

Custom hermetic seals and feedthroughs are designed to preserve a contamination-free environment while ensuring high optical clarity and structural stability. In applications like infrared imaging or laser targeting systems, a hermetically sealed viewport acts as a critical interface that transmits light while blocking moisture, pressure variation, and other environmental threats. These advanced assemblies must comply with military and aerospace standards such as MIL-PRF-13830, ensuring rugged performance from -100°C to 450°C.

Precision Engineering with Advanced Materials

What sets these glass to metal seals and ceramic to metal seals apart is the high degree of customization available. At Complete Hermetics, each viewport is engineered using the ideal combination of window and flange materials. Common viewport substrates include sapphire, fused silica, magnesium fluoride, and zinc selenide, each selected for its optical and thermal properties. These are paired with flanges made of Kovar, stainless steel (CF, NW), titanium, or aluminum—depending on the application’s specific sealing and mechanical needs.

With leak rates tested below 1×10⁻⁹ atm·cc/sec He, these viewports are built for environments where absolute integrity is required. Whether for use in deep-space missions or in sterile surgical imaging systems, these custom hermetic seals and feedthroughs provide unmatched protection and performance.

Choose a Trusted Hermetic Seal Manufacturer

When precision, durability, and compliance are mission-critical, trust a proven hermetic seal manufacturer. Complete Hermetics has years of experience delivering custom solutions for some of the most demanding industries in the world.

Looking for a reliable partner for custom hermetic windows and feedthroughs?

Contact Complete Hermetics today  to learn how our vacuum viewports, glass to metal seals, and ceramic to metal seals can help you achieve flawless performance under pressure.

Hermetic Seals: Custom Solutions for Harsh Environments

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The need for absolute containment, insulation, and durability in high-performance sectors drives the demand for reliable hermetic seals.  These components are critical to maintaining system integrity under extreme conditions such as pressure fluctuations, high temperatures, and corrosive environments. As a trusted hermetic seal manufacturer, Complete Hermetics delivers precision-engineered solutions in both glass-to-metal seals and ceramic-to-metal seals, customized for your specific application.

Glass-to-Metal Hermetic Seals

Glass-to-metal hermetic seals are the industry standard for cost-effective, high-strength, and corrosion-resistant protection. These seals are used in a wide range of hermetic products including electrical feedthroughs, vacuum systems, and RF or microwave applications. Complete Hermetics fabricates both compression and matched seals:

  • Compression Seals: Ideal for high-pressure use, with thermal expansion properties engineered for strength.
  • Matched Seals: Used when the coefficient of thermal expansion is closely aligned between materials, often in microelectronic and medical applications.

Our glass-to-metal hermetic feedthroughs are plated for enhanced corrosion resistance and electrical performance, with finishes like gold, silver, and nickel.

Ceramic-to-Metal Hermetic Feedthroughs

Where higher temperatures or voltages are required, ceramic-to-metal seals outperform their glass counterparts. At Complete Hermetics, we design and manufacture custom ceramic-to-metal feedthroughs and hermetic seals for use in aerospace, medical devices, and industrial power systems.

We also offer ceramic-doped glass seals—an advanced option that supports extreme heat tolerance up to 600°C, providing a lower-cost alternative to traditional ceramic sealing methods while maintaining high reliability.

Your Partner in Custom Hermetic Solutions

Whether your project requires miniaturized electrical feedthroughs or rugged hermetic connectors, Complete Hermetics has the expertise and flexibility to deliver. We specialize in custom hermetic seals and feedthroughs using advanced materials and tight manufacturing tolerances.

Connect with Complete Hermetics Today

If you’re looking for industry-leading performance and reliability, trust Complete Hermetics, your dedicated hermetic seal manufacturer. We provide customized, high-quality hermetic products to meet any challenge. Get in touch today to discuss your specific needs for glass-to-metal or ceramic-to-metal hermetic seals and feedthroughs.

Titanium headers

Lithium Battery Seals: Advanced Protection with Hermetic Precision

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Precision Engineering for Extreme Conditions

When it comes to ensuring the performance and longevity of lithium batteries, the importance of battery end seal technology cannot be overstated. Complete Hermetics specializes in custom glass-to-metal sealing techniques engineered for maximum reliability in lithium battery seals. These seals are designed to endure harsh environments—extreme temperatures ranging from -40°C to over +150°C, high electrical currents, pressure changes, electrochemical corrosion, and moisture sensitivity.

Unmatched Quality in Battery End Feedthrough Seals

Battery end feedthrough seals serve critical roles in a variety of industries, including medical devices, communication systems, military applications, sensors, and the automotive sector. These hermetic products ensure that lithium batteries remain safe, functional, and long-lasting under the most demanding conditions. With each seal, Complete Hermetics conducts a rigorous 100% leak test with a minimum leak rate of 1×10⁻⁸ cc He/sec and offers optional high-voltage breakdown and electrical isolation tests to meet industry-specific needs.

How Hermetic Seals Enhance Lithium Battery Performance

A properly sealed battery end cover ensures optimal power delivery and extends battery life. Missing or damaged seals allow energy to escape, drastically shortening battery lifespan. The glass-to-metal sealing process used by Complete Hermetics requires precision temperature control and material compatibility to form a lasting, cohesive seal. The result is a barrier that resists power loss and blocks the ingress of moisture and contaminants.

Why Dependability Matters

For applications where failure is not an option—pacemakers, weapons systems, or aerospace components—durability and precision are paramount. As a leading battery end seal manufacturer, Complete Hermetics delivers consistently reliable solutions that meet the highest standards of quality and performance.

Partner with Complete Hermetics

If you’re searching for a trusted expert in hermetic products, battery end seals, or battery end feedthrough seals, look no further than Complete Hermetics. Their custom engineering, stringent quality testing, and deep industry experience make them the ideal partner for high-performance battery sealing needs.

Contact Complete Hermetics today to design your next-generation hermetic solution—engineered for reliability, built to last.

Vacuum Viewports

Vacuum Viewports: Clear Performance Under Pressure

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In high-performance systems where vacuum integrity and optical clarity are paramount, vacuum viewports—also known as vacuum windows, hermetic windows, and hermetically sealed viewports—are indispensable. These components serve as critical interfaces between atmospheric and vacuum environments while allowing precise optical transmission for lasers, infrared, and imaging technologies. At the forefront of innovation, Complete Hermetics delivers customized hermetic products designed for challenging operational demands in space, defense, medical, and industrial sectors.

Custom-Engineered Hermetic Viewports

Unlike standard optical windows, hermetic viewports must maintain vacuum integrity under extreme environmental conditions. Complete Hermetics specializes in custom hermetic seals and feedthroughs, offering advanced window assemblies that conform to MIL-PRF-13830 and MIL-O-13830 standards. Whether for deep-space missions or high-power laser applications, these glass to metal seals and ceramic to metal seals  deliver unmatched performance and reliability.

Each unit is built to meet client-specific requirements—size, shape, optical transmission, thermal endurance—across a broad range of material configurations. Typical window materials include Sapphire, Fused Silica, Glass, Magnesium Fluoride, and Zinc Selenide. For flange materials, options such as Stainless Steel (CF/NW), Kovar, Titanium, and Aluminum ensure mechanical compatibility and chemical resistance.

Uncompromising Performance Standards

Every viewport from Complete Hermetics undergoes rigorous testing to ensure zero compromise on sealing integrity. These custom hermetic seals maintain leak rates of less than 1×10⁻⁹ Atm·cc/sec He and withstand bake-out temperatures up to 450°C, functioning reliably from -100°C in cryogenic setups to extreme high-heat applications. Optical elements are precisely aligned and polished to meet demanding military optical specifications.

Contact Complete Hermetics for Hermetic Products

When precision, durability, and customizability are non-negotiable, trust Complete Hermetics—a leading hermetic seal manufacturer—to deliver tailored solutions that power the world’s most advanced systems. From defense-grade laser optics to medical endoscopy and aerospace sensors, our hermetic products set the benchmark in sealing technology.

Contact Complete Hermetics today  to explore how our vacuum viewports, glass to metal seals, and ceramic to metal seals can elevate your mission-critical designs. Let us help you seal your success—hermetically.

Hermetic Headers: Protecting Electronics in the Harshest Environments

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In the world of advanced electronics, hermetic headers play a pivotal role in safeguarding components from hostile conditions. These specialized components are essential to industries such as aerospace, medical, and defense, where protection from moisture, gases, temperature extremes, and pressure variations is non-negotiable. As a trusted hermetic seals manufacturer, Complete Hermetics designs and fabricates high-performance headers and terminals that preserve the integrity of sensitive electronic systems.

Multiple Pin Headers for Superior Connectivity

Multi pin headers are crucial in connecting various electronic systems while maintaining an airtight seal. Built for durability and precision, these components are engineered to thrive in extreme environments. From aircraft control systems to implantable medical devices, multi pin headers ensure uninterrupted signal transmission without compromising the seal—delivering both performance and protection in equal measure.

TO Headers: Specialized Transistor Solutions

TO headers (transistor outline headers) are specially crafted for high-frequency and optoelectronic applications. Commonly used in TOSA (transmit optical subassembly) and ROSA (receive optical subassembly) configurations, these headers provide robust housing and hermetic protection for semiconductors and photonic components. At Complete Hermetics, every TO header is custom-designed to ensure the perfect fit and optimal function for your application.

Hermetic Connectors: Dependable Seals for Complex Systems

Another standout among hermetic products is the hermetic connector—essential for creating sealed electrical interfaces between different modules. These connectors are ideal for vacuum systems, undersea cables, or defense electronics where even the slightest leak could result in failure. Complete Hermetics offers both standard and custom configurations to meet your exact requirements.

Rely on Complete Hermetics for Your Hermetic Needs

When it comes to high-quality hermetic headers, connectors, and seals, Complete Hermetics is the name to trust. Our team combines expert engineering, precision manufacturing, and rigorous testing to deliver unmatched reliability. Whether you need multi pin headers, TO headers, or custom hermetic connectors, we’re here to meet your unique challenges. Contact Complete Hermetics today to explore our full line of hermetic products and discover how we can safeguard your technology from the inside out.

 

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.