Ceramic-to-Metal Seals and Feedthroughs for Harsh Conditions

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Why Choose Ceramic-to-Metal Seals

Ceramic-to-metal seals provide exceptional performance in environments where high temperatures, high voltages, and extreme pressures are present. Compared to glass-to-metal alternatives, ceramic-to-metal feedthroughs are designed for applications that demand the highest durability and reliability.

Applications of Ceramic-to-Metal Feedthroughs

Industries that depend on ceramic-to-metal feedthroughs include:

  • Aerospace and defense systems
  • High-voltage and power equipment
  • Vacuum and semiconductor chambers
  • Medical devices and diagnostic systems

These seals ensure maximum protection against leaks, electrical breakdown, and environmental damage.

Advantages of Ceramic-to-Metal Technology

Unlike glass seals, ceramic-to-metal hermetic seals can withstand harsher environments for longer periods. Their resistance to electrical stress and thermal shock makes them ideal for applications where standard sealing methods may fail. While production is more labor-intensive, the results deliver unmatched strength and durability.

Complete Hermetics Ceramic-to-Metal Solutions

Complete Hermetics specializes in custom ceramic-to-metal seals and feedthroughs, offering solutions built to precise customer specifications. Their expertise in engineering and materials ensures each product performs reliably, even in the most demanding conditions.

Applications include high vacuum feedthroughs, electrical feedthroughs, and advanced power or defense-related systems where precision sealing is critical.

Contact Complete Hermetics

As a trusted hermetic seal manufacturer, Complete Hermetics provides custom ceramic-to-metal seals and feedthroughs for industries worldwide. Our team will design and manufacture components to meet your exact requirements for performance and reliability.

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Hermetic Seals and Feedthroughs for Reliable Protection

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Why Hermetic Seals Are Important

Hermetic seals protect sensitive electronics from moisture, pressure, and gas leaks. In industries such as aerospace, defense, automotive, and medical, glass-to-metal seals and ceramic-to-metal seals provide airtight reliability where failure is not an option.

Complete Hermetics Seal Solutions

Complete Hermetics is a custom hermetic seal manufacturer specializing in glass-to-metal feedthroughs and ceramic-to-metal feedthroughs. Their engineers create custom prototypes and production-ready components to fit unique requirements across multiple industries.

Applications include:

  • Aerospace and defense electronics
  • High-voltage and vacuum systems
  • Medical devices, batteries, and sensors

Glass-to-Metal Seals

Glass is heated to a molten state and bonded to metal, creating a strong hermetic seal. These seals handle temperature changes, pressure variations, and corrosion resistance. Glass-to-metal feedthroughs are also cost-effective and versatile compared to ceramic alternatives. Options include compression seals for extreme pressure (up to 14,000 PSI) and matched seals for high thermal and mechanical shock resistance.

Ceramic-to-Metal Seals

For high-temperature, high-voltage, or harsh environments, ceramic-to-metal seals offer superior durability. While more labor-intensive to produce, they provide long-lasting performance in vacuum feedthroughs and electrical sealing applications.

Plating and Material Options

Complete Hermetics offers plating choices such as gold, silver, nickel, and tin to improve corrosion resistance and soldering capabilities. Materials include stainless steel, Inconel, Kovar, copper alloys, and high-performance ceramics, depending on application requirements.

Contact Complete Hermetics

As a leader in hermetic seals and feedthroughs, Complete Hermetics provides tailored solutions for both standard and custom designs. Whether you need glass-to-metal seals, ceramic-to-metal seals, or specialized hermetic feedthroughs, we deliver unmatched reliability.

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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 1×10⁻⁹ 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.

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

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.

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.

Which Is the Best Hermetic Seal: Glass or Ceramic?

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If you are in the market for a hermetic seal, you may wonder if it is better to purchase a glass to metal seal or a ceramic to metal seal. Each variety has its respective advantages and disadvantages. Some people prefer to stick with one kind, while others use different seals depending on the function.

Glass to Metal Seal and Feedthrough

A glass to metal seal is made with glass molten right to the metal. This provides an advantage of a secure seal that is connected directly with the metal. Glass is thought of as fragile, but it has a high level of compression strength. It is also a less expensive alternative to ceramic seals.

Ceramic to Metal Seal

A ceramic to metal seal is more costly than a glass to metal seal, and some say the difference in price is worth it. Ceramic can be made in custom designs and show more resistance to mechanical and thermal shocks. However, these seals can have a greater tendency to chip than glass does, but can last longer before these chips form.

Some people swear by their favorite kind of glass to metal seal, while others prefer ceramic. The kind you choose depends on the job you need to do, cost considerations and how much shock you want the seal to withstand.

Understanding Hermetic Seal Types and Uses

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A hermetic seal is known as a go-to choice for superior protection when it counts. Whether you require protection from air, gasses, moisture, soil or any other hazard, hermetic connections are the gold standards across many industries. But a seal protects best when it is the right seal for the job. Learn more about the main types of hermetic sealing and find out which ones are best for your job.

To start with, there are three main types of airtight seal. They are:

  • Glass to glass seal
  • Glass to metal seal
  • Ceramic to metal seal

Glass to Glass Hermetic Seals

When two glass pieces require a perfectly sealed environment, glass to glass sealing is the choice. As many as five layers may be involved in the creation this type of seal, which is often used in sealing flat windows, glass tube components and glass envelopes to name just a few applications.

Glass to Metal Seals

Glass and metal fused together to form leak-tight joints are glass to metal seals. These types of seals are all around you every day, due mainly to their versatility and strength.  Known for their exceptional hermetic values, these types of seals are critical in the construction of vacuum tubes, pressure tight glass windows and any number of electronic components to name just a few applications. GTMs are especially useful in the lighting industry, with the most common application being the seal on a lamp bulb.

 Ceramic to Metal Seals

Ceramic to Metal seal is more costly and time consuming to make than a glass to metal seal. Some say it is worth for applications where high operating temperatures, high voltage and harsh environments are required. Ceramic can be made in custom designs and show more resistance to mechanical and thermal shocks.

When zero porosity is required, hermetic sealing is the reliable choice. Know your options by understanding the different sealing possibilities and ensure you’re choosing the best sealing method.