Douglas Electrical Components manufactures standard and custom hermetic electrical feedthroughs in various housing styles and configurations. Depending on the application, existing hardware, or design constraints, Douglas will partner with you to find the right housing to meet your application demands. With in-house CNC and machine tooling as well as a strong network of outside resources, our team is prepared to support custom designs in competitive lead times while keeping costs down and quality up.
Hermetic assemblies are available in a variety of materials from plastic, brass, and aluminum to stainless steel and specialty nickel alloys for more corrosive applications. We have the capability to also use customer-supplied housings to directly cast the electrical connection to hermetically seal it to maintain a low profile, light weight, or seal within complex geometry.
Our high-strength, hermetic epoxy is chemically inert, providing a hermetic seal between any conductor type and the mechanical interface. This includes wires, cables, connectors, printed circuits, flex/rigid circuits, and optical fibers. In the development of a hermetic assembly, incorporating Design for Manufacturing (DFM) principles involves optimizing the design to ensure that the manufacturing process is efficient, cost-effective, and of high quality, leading to a seamless production of the feedthrough while minimizing potential issues and delays. Our team will integrate other electrical components into the design such as shielding, connectors, and cable harnesses directly into the assembly for plug-and-play operation.
Utilizing LEAN manufacturing, our assembly process is designed to support production volumes from single piece orders to hundreds of thousands of pieces. Our feedthroughs and assemblies are manufactured in Randolph, NJ to ISO 9001 standards with IPC-620 trained technicians (AS9102 First Article Inspections available upon request; contact factory).
Features
WHY CHOOSE DOUGLAS?
- Build More – Buy Less – Create high density hermetic solutions using our proprietary epoxy technology to create an air- and moisture-tight seal of virtually any conductor, circuit, or optical fiber.
- Get it Faster – From rapid prototypes to full scale production, Douglas Electrical Components manufactures standard and custom solutions for MIL/Aero applications in our NJ facilities on schedule.
- Plug & Play – With a Design for Manufacturability mindset and technology with ultimate design flexibility, our application engineers will partner with you to design a hermetic solution as a second source or new design to optimize it for your operational success. Save time and money with Douglas Electrical Components.
MARKET CAPABILITIES
- ISO 9001:2015
- ISO 14001:2015
- ITAR DDTC Registration
- UL/cUL 1203, UL 886, UL 674, and UL 913
TECHNICAL ADVANTAGES
- ITAR-, DDTC-, DFARS-, Conflict Materials-, and ROHS-compliant assemblies.
- AS9102 First Article Inspections available upon request; contact factory.
- Transform standard non-hermetic connectors into hermetically sealed assemblies.
- Electrically and hermetically tested to ensure quality.
- IPC-620 certified technicians provide the basic hermetic seal and cable harness work like labeling, bundling, twisting, shielding, filtering, solder, and crimping.
- Chemically compatible with a variety of liquids
and gases - Choose from mechanical interface materials including MIL-certified stainless steel, brass, plated steel, or lightweight options of aluminum, titanium, and plastics
- Use a variety or combination of wire and cable materials, wire conductor types, gauges, and lengths
- Integrate hermetic seals directly into active sensing
elements, circuit boards, and flex circuits to save
weight and space
FAQ
What are some standard housing materials?
Douglas offers a variety of standard housing materials including brass, aluminum, and stainless steel. Additionally, we can machine and hermetically seal plastics, specialty alloys, and more. The material type will depend on the operating conditions such as the pressure and temperature; contact our design engineers to review your application.
How do you test your housings for leaks?
Depending on the fitting and customer requirements, we have two standard tests. First, we offer helium leak testing via mass spectrometer. Second, we can offer pressure testing in-house up to 15,000 PSI for high pressure applications. All assemblies are 100% tested (no lot testing) to ensure each hermetic assembly meets our quality standards. Our in-house machine shop ensures that tooling is developed to properly test and verify each assembly.
How do I calculate the wire density in a feedthrough?
Our standard catalog has some basic information on wire density, yet it is best to contact our team. We will review your requirements and combine the correct wire gauge and conductor count for the housing size to ensure the proper fit, performance, and highest density possible while maintaining all electrical performance properties.
Do you offer hermetic assemblies for explosion-proof applications?
Yes. Our NPT line of hermetic electrical feedthroughs (commonly referred to as conduit seals or wire bushings) are available with approval to Class I Division 1 Explosion-proof. Contact us for ATEX availability as well.
Can the housing be designed with additional features such as integrated shielding or grounding?
Yes. Our technical sales engineers will work with you and your team to integrate connectors, shielding, grounding or any other design features to make the installation process seamless.
How do you address potential issues like outgassing in vacuum or space applications?
Douglas employs a low-outgassing hermetic epoxy to its hermetic electrical feedthroughs and assemblies. Check our Documents tab to download information on outgassing.
Image Library
Hermetic USB 3.0 Feedthru
Hermetic USB connector with custom radial O-ring seal for high pressure
Radial Seal Close-up
Hermetic wire feedthrough with radial o-ring seal
KF Hermetic Fiber Optic Feedthru
Custom KF feedthrough with optical fibers
Dual Circuit Seal
Dual circuit hermetically sealed inside custom flange
Custom Wire Feedthru
hermetically sealed wires terminated in connector for high pressure applications
Custom Flange pin sealed
customized flange hermetically sealed with integral pins
Epoxy-sealed Pins in Custom Housing
Hermetically seal pins within a custom housing.
Portplate rectangular, wire feedthrough
Hermetically Sealed Plastic Connector
customized plastic connector with integral pins for pressure application
Hermetic SMA Coaxial Feedthru
Hermetic SMA coaxial feedthrough with vacuum face seal interfaces and four connections
Hermetic MTP Fiber Optic Feedthru
Hermetic optical fiber feedthrough with MTP connectors and vacuum face seal
CF Feedthrough with RJ45 and D-sub connectors
Vacuum view of CF hermetic feedthrough featuring RJ-45 and D-sub connectors
Dual USB Hermetic Feedthrough with KF flange
Hermetic USB feedthrough with two USB-A connectors in KF type flange
Multi-conductor type CF Feedthru
Hermetic CF wire and thermocouple wire feedthrough with integral connectors
CF Feedthru Side View
Side view of a hermetic electrical feedthrough with CF Flange
CF hermetic feedthrough with milspec connector
CF hermetic feedthrough with MIL-spec connector
D-sub & RJ45 CF Feedthrough
CF electrical feedthrough with D-sub and RJ45 ethernet connectors
Hermetic NPT Wire bushing
Explosion-proof rated wire bushing with brass fitting and labeled conductors
NPT Fiber Optic Wire Bushing
Fiber optic NPT threaded electrical feedthrough conduit seal
Hermetic NPT feedthrough with push/pull connector
Hermetic NPT electrical feedthrough with push/pull connector provides a compact footprint with inexpensive sealing method.
Automotive Hermetic Wire Harness
hermetically sealed automotive wire seal with integral connectors for plug-and-play install
CF Wire Feedthrough
Hermetic wire feedthrough with customer-specified conductors
Hermetic Bulkhead SMA Feedthrough
Hermetically seal multiple SMA connections in a single vacuum face seal assembly
Compact Hermetic USB Assembly
USB-C hermetic bulkhead connector with small jamnut design
USB Wire and Connector Feedthroughs
Hermetically seal USB connections with wire or connector interfaces for vacuum and pressure applications
hermetic bulkhead hdmi-feedthrough side
Hermetic bulkhead HDMI-feedthrough is designed with a face seal to simplify installation and transmit signal in vacuum or positive pressure.
15 position Hermetic Micro-D reversible hermetic feedthrough angled pin view
15 position Hermetic Micro-D reversible hermetic feedthrough angled pin view
Dual D-sub Hermetic Connector
PotCon Dual sub-D hermetic connector on rectangular flange creates a higher density connection with a single penetration point.
RBTW custom d-sub seal in customer housing
RBTW custom d-sub hermetic seal with integral wires. The hermetic connection is installed in a customer designed and supplied housing.
Custom Housing Feedthru
Custom feedthrough design for high vacuum applications
Hermetic 38999 Assembly Side View
Create a customized hermetic seal for pressure applications
Multi-flex hermetic feedthrough
Multi-flex hermetic feedthrough circuit with face seal housing and jam nut
Documents & Downloads
Literature
Douglas Electrical Components Catalog
PotCon Catalog
Hermetic Plate Assemblies for Aerospace & Defense
Datasheets
D-sub Hermetic Connector Feedthroughs
Micro-D Hermetic Connector Feedthroughs
Push-through Feedthroughs
StudSeal Hermetic Terminal Seals
Whitepapers
Types of Hermetic Seals: Glass-to-Metal Vs. Epoxy
Designing with CircuitSeal
Wire Bushings for Hazardous Locations
Integrated Epoxy Feedthroughs Improve Fuel Pump Reliability
When Wire Feedthroughs Make Sense
Material Data
RoHS Certificate of Conformance
REACH Statement
NASA Outgassing Report, 1469-1481
NASA Outgassing Report, 29885-1481
NASA Outgassing Report, 7113-1470
Epoxy Data, 29885-1470
Epoxy Data, 7113-1481
Certificates & Standards
ISO 9001:2015 Certificate
ISO 14001:2015 Certificate
ITAR-DDTC Registration
UL984 Standard for Hermetic Refrigerant Motor Compressors
UL 1203 Explosion-Proof and Dust-Ignition-Proof Electrical Equipment for Use in Hazardous (Classified) Locations
UL 1203 Conduit fittings for use in Hazardous Locations