Hermetic Feedthrough & Bulkhead Connectors
Hermetic Feedthrough & Bulkhead Connectors
Overview
- Prevents hazardous gas or fluid migration, ensuring ultimate safety for critical, high‑risk systems
- Handles extreme bidirectional differential pressures up to 10,000 PSI on designated subsea configurations without structural failure
- Operates flawlessly in punishing environments, tolerating thermal shocks from -55°C to +175°C (higher‑temperature models available for specific needs)
- Glass‑to‑metal sealing eliminates degradation, significantly extending equipment lifespan and reducing downtime
- Delivers stable, uncorrupted data and power transmission even under severe operational stress
- Compact bulkhead design optimizes valuable panel space while maintaining robust heavy‑duty performance
- Premium stainless steel and gold‑plated contacts withstand harsh chemicals and marine saltwater
- Available in configurations that fully conform to strict military standards (MIL‑PRF / MIL‑DTL), simplifying your system integration and qualification
- Flexible jam‑nut or weld‑mount configurations fit seamlessly into any existing enclosure design
- Customizable pin arrangements and shell sizes match your exact application specifications perfectly
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Hermetic Bulkhead Connectors | MIL-PRF & MIL-DTL Hermetic Sealed Interconnects
Hermetic bulkhead connectors provide reliable, gas-tight electrical interconnection through enclosure walls, bulkheads, and pressure boundaries. By leveraging advanced glass-to-metal sealing technology, these hermetically sealed bulkhead connectors actively protect sensitive internal electronics from moisture, contaminants, and environmental stress in vacuum, subsea, aerospace, military, and industrial systems.
As a trusted hermetic connector manufacturer, we support prototyping and volume production with low MOQ, custom engineering, and dependable lead times for demanding applications where sealing integrity and long-term reliability matter most.
Why Choose Our Hermetic Bulkhead Connectors
Reduce Leakage Risk in Sealed Systems
Non-hermetic interfaces can create dangerous leak paths at pressure boundaries. To counter this, we engineer our glass-to-metal hermetic seals to maintain system integrity across vacuum chambers, subsea enclosures, and aerospace platforms.
Minimize Downtime from Vacuum Failure
Even a small leak can interrupt testing or production schedules. Therefore, our quality control team helium leak tests every single hermetic connector, with typical leak rates reaching ≤ 1 × 10⁻⁹ mbar·L/s on qualified series (exact values depend on connector type and configuration), ensuring reliable pressure stability in critical systems.
Ensure Long-Term System Reliability
Our hermetic bulkhead connectors thrive in challenging operating conditions. They deliver high vibration resistance, support extended mating life (up to 500 cycles typical for many series, exact life varies by model), and operate across wide temperature ranges (e.g., -55°C to +175°C for selected models), with final ratings matched to your application requirements.
Reduce Redesign Cost in OEM Integration
Custom flange shapes, mixed-signal layouts, and fast engineering reviews drastically shorten redesign cycles. As a result, you can accelerate product integration into your specific application.
Core Benefits of Our Hermetic Bulkhead Connectors
Guaranteed Hermetic Seal Performance
Our team 100% helium leak tests every connector, achieving leak rates as low as ≤ 1 × 10⁻⁹ mbar·L/s (typical for qualifying series), with exact limits specified per product configuration.Proven Military and Aerospace Reliability
These rugged components effortlessly endure severe vibration, shock, and extreme temperature environments.ASTM E-595 Screened for Low Outgassing
Materials are evaluated per ASTM E-595 vacuum materials screening test for total mass loss (TML) and collected volatile condensable material (CVCM), providing a reliable screening baseline for vacuum compatibility. This makes them well-suited for high and ultra-high vacuum applications. Note: ASTM E-595 is a materials screening method and does not alone guarantee system-level contamination-free performance.Rugged Construction for Harsh Environments
Stainless steel housings and gold-plated contacts provide superior durability and long-term corrosion resistance.Custom Bulkhead Engineering Support
We offer tailored flange shapes, flexible contact layouts, and seamless mixed-signal integration to fit your exact needs.
Hermetic Bulkhead Connector Types
| Type | Common Standards | Typical Applications | Pin Range | Seal Technology |
|---|---|---|---|---|
| Circular Hermetic Bulkhead | MIL-DTL/MIL-PRF-38999 class, MIL-DTL-83723 | Avionics, radar, aerospace vacuum, subsea | 4–61 pins | Glass-to-metal (GTMS) |
| D-Sub Hermetic Bulkhead | MIL-PRF-24308 (MIL-DTL-24308 style) | Standard/high-density signal, tactical communications | 9–50 positions | Glass-to-metal (GTMS) |
| Micro-D Hermetic Bulkhead | MIL-PRF-83513 | Compact high-density interconnects, satellite, military | 9–100 pins (typical) | Glass-to-metal (GTMS) |
| Coaxial Hermetic Bulkhead | SMA, BNC, N-type | RF signal, radar, video, test equipment | 1 coax | Glass-to-metal (GTMS) |
| Custom Rectangular Bulkhead | OEM/custom layouts | Mixed power/signal/coax, specialized enclosures | Custom | Glass-to-metal (GTMS) |
Note: Seal technology and exact standards may vary by product configuration and application requirement.
Complete Technical Specifications
| Parameter | Specification |
|---|---|
| Seal Type | Glass-to-metal hermetic seal (GTMS) |
| Leak Rate | Typical ≤ 1 × 10⁻⁹ mbar·L/s (helium tested); consult datasheet for specific series |
| Operating Temperature | Standard ranges from -55°C to +175°C; exact range varies by series (e.g., D-Sub often -55°C to +125°C) |
| Pressure Rating | Up to 10,000 psi on designated subsea configurations (configuration dependent) |
| Voltage Rating | Up to 500V AC (configuration dependent) |
| Current Rating | Up to 25A per contact (varies with contact size and series) |
| Insulation Resistance | ≥ 5,000 MΩ at 500 VDC |
| Contact Resistance | ≤ 10 mΩ (initial) |
| Vibration Resistance | 50G @ 10–2000Hz (typical) |
| Shock Resistance | 30G @ 11ms half-sine (typical) |
| Salt Spray Resistance | 500+ hours (MIL-STD-202 Method 106, may vary by finish) |
| Mating Cycles | 500+ cycles typical for many series (final rating depends on model) |
| Housing Material | Stainless steel 300/400 series |
| Contact Plating | Gold, 50 microinches minimum |
Note: All specifications are representative and may vary by connector type, configuration, and qualification level. Please refer to individual product datasheets or contact us for exact values.
Applications by Industry
| Industry | Typical Use Cases | Hermetic Benefit |
|---|---|---|
| Military and Defense | Avionics, radar systems, tactical communications, weapon systems, military vehicles | Delivers superior vibration/shock resistance and full MIL-spec suitability |
| Aerospace and Space | Satellites, spacecraft, vacuum chambers, thermal vacuum testing, aerospace instrumentation | Materials screened per ASTM E-595 support low-outgassing and UHV compatibility |
| Subsea and Marine | Underwater sensors, offshore exploration, submersibles, deep-sea robotics, sonar systems | Provides robust pressure resistance alongside salt spray defense |
| Medical and Scientific | MRI equipment, vacuum pumps, SEM/TEM, semiconductor tools, research labs | Guarantees strict contamination control and ultra-low leak performance |
| Industrial Automation | High-pressure hydraulics, chemical processing, harsh environment robotics, oil and gas | Offers durable sealing paired with excellent temperature tolerance |
Hermetic Bulkhead Connector Selection Guide
To help you identify the right hermetic bulkhead connector, we have organized our recommendations below based on your application priority and engineering constraints.
| Application Priority | Recommended Type | Key Engineering Reason |
|---|---|---|
| Ultra-High Vacuum (UHV) | Circular (MIL-DTL-38999 class) | GTMS circular designs help maintain hermetic integrity under thermal cycling |
| High-Density Signal | D-Sub (MIL-PRF-24308 style) | Compact layout and efficient pin density optimize signal-heavy systems |
| Compact High-Density Interconnects | Micro-D (MIL-PRF-83513) | Small form factor with robust vibration/shock resistance for demanding tactical and space applications |
| RF / Microwave Signal | Coaxial (SMA / BNC / N-type) | Controlled impedance guarantees stable signal transmission |
| Mixed Power + Signal | Custom Rectangular | Combines power, coax, and signal in one shell to reduce interface count |
| Deep-Sea Subsea | Circular (Threaded Flange) | Heavy-duty construction provides strong pressure boundary performance |
| Tactical Military | Micro-D / D-Sub | These compact, rugged interfaces easily withstand vibration and shock |
FAQ
What is a hermetic bulkhead connector used for?
A hermetic bulkhead connector passes electrical signals or power through a sealed enclosure wall or bulkhead without allowing air, gas, moisture, or contaminants to leak through. Engineers commonly specify them for vacuum chambers, aerospace systems, subsea equipment, and military applications.
What is the leak rate of your hermetic bulkhead connectors?
Every hermetic bulkhead connector undergoes helium leak testing, with leak rates as low as ≤ 1 × 10⁻⁹ mbar·L/s achieved for many series. Exact leak rate limits depend on the specific connector type and configuration, ensuring pressure stability in high-reliability applications.
Are your hermetic bulkhead connectors vacuum compatible?
Yes. Our connectors employ materials selected in accordance with ASTM E-595 vacuum screening criteria (TML and CVCM) to support high and ultra-high vacuum compatibility. While this screening indicates low outgassing tendency, system-level performance should be validated for your specific process conditions.
What is a MIL-PRF or MIL-DTL hermetic bulkhead connector?
This refers to a hermetically sealed connector that explicitly meets military performance (MIL-PRF) or detail (MIL-DTL) specification requirements. Consequently, it guarantees the ruggedness, reliability, and environmental performance needed for defense and aerospace applications.
Can hermetic bulkhead connectors withstand subsea pressure?
Yes. We engineer selected configurations specifically for high-pressure subsea applications, achieving pressure ratings up to 10,000 psi on designated subsea models. Please consult specific product data for exact ratings.
How does glass-to-metal sealing work in connectors?
Glass-to-metal sealing uses thermal fusion to bond glass directly to metal. This fusion creates a highly durable hermetic barrier that completely blocks air, gas, and moisture ingress.
What flange options are available for hermetic bulkhead applications?
Our standard range includes threaded flange, square flange, and vacuum-compatible options such as CF, KF, and ISO. In addition, our team can design custom flanges to match your exact dimensions.
What is the difference between a hermetic bulkhead and a hermetic feedthrough connector?
Hermetic bulkhead connectors typically feature a plug-and-receptacle mating interface on both sides of a wall or panel. In contrast, hermetic feedthrough connectors often act as single-ended solutions designed for permanent or direct penetration through a boundary.
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Strict Production Process
Engineers develop optimized electronic circuits and structural designs based on real application needs.
High-quality components and materials are carefully selected from trusted suppliers to ensure long-term reliability.
Automated SMT and precision soldering technologies are used to build stable and high-performance circuit boards.
Sensor elements or connector terminals are assembled with the PCB and housing to ensure accurate operation and strong mechanical stability.
Each product undergoes strict calibration and functional testing to guarantee accuracy and stable performance.
Every unit is carefully inspected, labeled, and securely packaged to ensure it arrives safely and performs reliably for your applications.
Strict Production Process of Yafeite
