Hermetic Connectors vs. Standard Connectors

Understanding the difference between hermetic connectors and standard connectors is critical when selecting components for sealed systems, high-vacuum equipment, or pressure environments. While both are used to transmit power, data, and signals, their structural integrity, sealing performance, and suitability for harsh environments are significantly different. Sealing Capability

Hermetic connectors are designed to create a 100% leak-tight barrier. At Douglas Electrical Components, we use high-performance epoxy to achieve true hermetic sealing with leak rates as low as 1×10⁻⁹ cc-He/sec. This level of sealing is essential in applications where gas or liquid ingress must be prevented to maintain system performance. In contrast, standard connectors may use gaskets or mechanical seals, which can degrade over time, allowing air, moisture, or contaminants to pass through.

Construction Method

Hermetic connectors are manufactured by bonding wires, fiber optics, or pins directly into the connector body using low-outgassing epoxy. This method ensures long-term integrity even under extreme pressure or temperature conditions. Standard connectors typically rely on compression fittings, O-rings, or mechanical mating parts. These can loosen, wear out, or fail due to vibration, temperature cycling, or chemical exposure.

Environmental Resistance

Epoxy-sealed hermetic connectors from Douglas Electrical are built to withstand high vacuum, pressure differentials, temperature extremes, and exposure to corrosive media. They perform reliably in demanding environments where conventional connectors would fail. Standard connectors, while functional in non-critical conditions, are not designed for vacuum chambers, cleanrooms, or pressurized systems, where even minor leaks can compromise operations.

Application Suitability

Hermetic connectors are commonly used in semiconductor manufacturing, aerospace systems, vacuum environments, gloveboxes, cryogenics, and defense equipment. These applications require stable, sealed interconnects that won’t degrade under stress. Standard connectors are suited for general industrial and commercial applications where exposure to environmental factors is minimal and sealing is not a requirement.

Customization and Integration

Douglas Electrical offers hybrid hermetic connector assemblies that combine power lines, signal wires, fiber optics, thermocouples, and coaxial cables into a single sealed interface. This integration reduces weight, minimizes bulkhead penetrations, and simplifies system architecture. Standard connectors generally lack the flexibility to combine multiple media types in a single assembly and often require separate connectors for each function.

If your system requires long-term reliability in high-vacuum, pressurized, or hazardous environments, hermetic connectors offer unmatched performance and sealing capability. Our epoxy-sealed feedthroughs and connector assemblies are engineered to meet strict performance demands across industries. With Douglas Electrical’s experience in custom hermetic solutions, you gain access to high-integrity connectors that ensure leak-free performance and system longevity.

Chris Rempel, with over two decades of experience, serves as the Director of Sales and New Product Development at Douglas Electrical Components.