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In extreme environments, connectors need extra protection. Various applications within the military, offshore, commercial, and industrial industries are exposed to harsh conditions such as high pressures and altitudes, temperature variations, extreme depths, corrosive materials, moisture, vibration, and more. Hermetically sealed connectors are specially designed to stand up to these and other challenges.

Hermetic connectors prevent air, gases, and liquids from entering the vacuum-sealed interior. In testing, they must be able to withstand pressures of 10,000 psi and higher while ensuring a stable pressure differential both inside and outside the assembly. They must also show no detectable gas or fluid leakage.

Advantages of Hermetic Connectors

Hermetically sealed connectors can protect against a wide range of conditions that would otherwise cause damage. These include:

  • Thermal shock
  • Humidity
  • High altitude
  • Vibration
  • Extreme temperatures

The right connectors can stand up to temperatures that range from -100° C to 200°C without suffering damage from thermal shock. They can also maintain a stable pressure differential under pressures of 10,000 psi or more. Your intensive applications require connections that perform no matter what the environment.

How Are Hermetically Sealed Connectors Constructed?

When constructing hermetically sealed connectors, the connectors can use stranded or solid plated copper conductors, as well as insulated conductors. They may also contain brass, copper, or nickel iron pin contacts and fiber optic cables. Most are made of durable metals such as stainless steel, glass, and nickel iron, as these materials are capable of withstanding harsh environments. If weight is a concern, aluminum alloy shells can be used, which can reduce the weight of the connector significantly.

Most hermetically sealed connectors are glass sealed. This is because glass creates a rigid form that the metal shell compresses against, resulting in a hermetic seal. The glass is bonded to and provides support for the contacts. In some cases, glass can create excessive weight. In these applications, epoxy seals are used instead.

Applications of Hermetically Sealed Connectors

Many industries and applications rely on various measuring, sensing, and control systems for their operations. From navigation systems and power generation to medical implants and laser technology, these systems require components that can operate in extreme environments while retaining their original properties and offering reliable, error-free performance. Hermetically sealed connectors stand up to some of the most demanding applications.

Industries that benefit from hermetically sealed connectors include:

  • Military/aerospace/defense
  • Transportation
  • Energy production
  • Industrial
  • Medical

Hermetically Sealed Connectors from Connectronics

The right hermetically sealed connectors can stand up to the stresses of your application. At Connectronics, we design and build hermetically sealed connectors capable of withstanding a wide range of harsh conditions. Our state-of-the-art environmental and electrical testing equipment allows us to test all of our connectors to ensure they meet the requirements of your application while providing reliable operation and long service life. To view our product offerings, visit our product catalog. For help finding the best hermetically sealed connector for your unique requirements, contact the experts at Connectronics today, and we’d be happy to discuss your application.


It feels like it was just yesterday that we were looking ahead to 2016 and now we’re already looking back! A year it has been – as we continued to make connections throughout industries that advance innovations and develop high-tech systems. So, what were the main highlights?

Our focus this year was to continue to meet the high tech needs of the military and aerospace industries as we outlined in our ‘16 Outlook. At the beginning of the year, we announced the expansion of our product lines for more technologically advanced electronics. These new products have been incorporated into systems for aerospace, avionic, medical, fusion power, and many more industrial applications.

To continue to meet the demands for our connectors, our expansion plans were in full gear. We gave you a glimpse into our new production capabilities and the construction of our new building to house additional manufacturing operations. Through all the construction and mayhem of activity at our facility, we didn’t forget what has made us a leader in supplying reliable and robust connectors—customer satisfaction. We reiterated our leadership in our August blog. Our impeccable reputation is strengthened by our satisfied customers. From our high-quality connectors and interconnection systems to our dependable customer service, Connectronics delivers an unmatched customer service experience with each year topping the last.

In the past 12 months, we have continued our niche—manufacturing specialized high voltage connectors, high current connectors, underwater connectors, and cable assemblies that provide outstanding reliability and operation. Our experts continued to work with professionals in the fields of avionics, analytical instrumentations, medical devices, electronics, aerospace, and nuclear – just to name a few – to meet the needs and expectations of their final products.

2016 was a great year for us, and we are looking forward to continuing to exceed our customer’s expectations in 2017!

From all of us at Connectronics to all of our customers and contacts in the industries we serve, wishes for a Happy Holiday season and a healthy New Year!

Looking for a connector over the holiday season? Find the latest on our Twitter, LinkedIn, or contact us today!


As we know, water and electricity don’t mix. In fact, it is a deadly and disastrous combination; however, there are many applications that require electrical equipment to be in or near water. It is imperative that the right equipment is used to provide effectiveness and safety as a result of this factor.

One of our most specialized cable and connector series is designed and manufactured to UWC Series Connectorsmeet the requirements of underwater applications. With a critical water sealing interface, the UWC Series provides the reliable performance needed in underwater cables and connectors. Featuring stainless steel hardware and water sealing over-molding, our components are the first choice for a wide range of industries, including water treatment to scientific research.

It is our work with numerous industry professionals that allows us to understand the specific and precise needs of working in a water environment. In a previous post we touched on our partnership with Yellow Springs Instruments (YSI). YSI develops global water monitoring solutions for clients concerned with climate change, drought, floods, clean drinking water, healthy ecosystems, and storm water runoff. Our 20-year connection (pun intended) has enabled YSI to develop instruments and data collection platforms for environmental testing and monitoring.

In order for these instruments to work effectively, the connectors must be secure and reliable. That is why YSI has chosen Connectronics as a partner. Our connectors can meet the needs of demanding underwater conditions. The cables have PVC insulation, a foil shield, polyurethane jacket and the plug, itself, is insulated with neoprene rubber. With a proper seal, the glass-filled epoxy, insulated receptacle, and stainless steel connector all work together to ensure that the connections are protected against water infiltration.

Applications for YSI and Connectronics equipment hit close to home as Ohio faces water
crisis’ such as blooming algae that threatens the water in Lake Erie. Last year was the first year the local area started to monitor the Lake Erie Algae Image 2water quality and found large concentrations of blue-green algae. This ongoing threat continues to be a cause of concern for “conservation groups and Ohio business, farming, and government officials.” As an Ohio native business, we are just as concerned and have a stake in handling this issue successfully.

As the old saying goes, “Water, water everywhere but not a drop to drink.” With the monitoring solutions of YSI and the interconnection components supplied by Connectronics, we feel confident that reliable and valuable information will be available to scientists, officials, and policymakers for a solution to keeping the water in oceans, streams, and lakes safe.

For further information on our products and services that we offer give us a call at 800-965-0020.

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