Electrical Feedthroughs | PAVE Technology

Circular, D-Sub, RF Coax, Thermocouple & High-Voltage Hermetic Feedthroughs

PAVE-Seal® manufactures hermetic electrical feedthroughs and hermetically sealed connectors used as sealed bulkhead electrical connectors for vacuum, pressure, and harsh-environment applications. Our product line includes hermetic circular connectors, D-Sub connectors, RF coax feedthroughs, Ethernet LAN feedthroughs, thermocouple feedthroughs, and high-voltage hermetic seals, providing leak-tight electrical transmission across environmental boundaries while maintaining signal integrity and electrical isolation.

All hermetic feedthroughs are available in standard and custom configurations, engineered for vacuum systems, pressure vessels, and extreme environments, with U.S.-based manufacturing and engineering support.

Custom pin counts & voltages
RF, thermocouple & Ethernet options
Custom Vacuum feedthrough designs for OEM & harsh environments
U.S. manufacturing & engineering support

Resources and Downloads

Below are standard bulkhead electrical connectors and vacuum feedthrough drawings, organized by conductor count, mounting style, and physical configuration.

SPF12 Hermetic Electrical Feedthrough with external C-ring

Hermetic Circular & Bulkhead Electrical Connectors

Hermetic circular connectors are specialized components that enable electrical conductors—such as wires, cables, or multi-pin configurations—to pass through a sealed barrier without compromising airtightness or structural integrity. Unlike standard wire passthroughs, bulkhead electrical connectors maintain a gas-tight seal even under significant pressure differentials or in ultra-high vacuum environments.

Features & Capabilities

High Voltage & RF Hermetic Feedthroughs

Hermetic & Bi-Directional Sealing

PAVE-Seal® systems maintain hermetic integrity for vacuum and pressure from either direction.
Suitable for environments where pressure differentials exceed normal atmospheric conditions.

Wide Operating Temperature Range

Engineered to operate across extended temperature ranges (customizable by design and materials).

Leak-Tight Performance

All seals pass stringent helium leak testing at rates as low as 10-9 cc/sec, depending on configuration. This ensures minimal gas leakage in critical systems.
Material & Environmental Resistance
Designed for chemical resistance (solvents, fuels, oils, gases) and low outgassing performance for high-vacuum applications.

Custom & Standard Solutions

Available in standard designs for fast deployment or custom configurations engineered to match your exact electrical, pressure, or vacuum requirements.

Typical Applications

Hermetic electrical feedthroughs are used where both electrical connectivity and environmental isolation are required, including:

Vacuum chambers and UHV systems
Aerospace & defense systems
Industrial process equipment
Semiconductor fabrication tools
High-pressure vessels

These feedthroughs ensure electrical signals and power pass through sealed barriers without compromising vacuum or pressure environments.

Product Specifications

Leak Performance: Helium leak rates to ~10-9 cc/sec (varies by design)
Operating Temp Range: Customizable (e.g., −200°C to +200°C)
Conductors Supported: Single wires, multi-wire bundles, cable assemblies, coaxial cables
Environmental Resistances: Low outgassing, chemical resistance

Design & Customization Options

PAVE offers:

Standard hermetic feedthroughs with documented performance
Custom engineered feedthroughs tailored to:
- Specific cable or wire types (including coaxial, thermocouple, fiber optic, multi-pin configurations)
- High pressure or vacuum specifications
- Unique mechanical or electrical requirements

Simply upload your drawing or provide a sketch to receive a competitive quote or design consultation.

Why choose PAVE-Seal® Bulkhead electrical connectors?

Industry-Trusted Performance

Proven hermeticity and durability across varied environments.
Suitable for critical systems where air or gas leakage is unacceptable.
Engineering Support Included

Our team provides responsive design support and application guidance from concept through production.

Hermetic Electrical Feedthroughs Specifications

HERMETIC EPOXY TEMPERATURE RATING (Epoxy is proprietary and not sold separately)

PAVE Wire Seal® 150	PAVE Wire Seal® 200	PAVE Wire Seal® 200UL94VO
-200° to 125° C	-200° to 150° C	-200° to 200° C

-200C may be possible when designed for use with a Teflon o-ring

Any type or size of wire or cable may be specified including coaxial cables, thermocouple wire pairs, high voltage wires, fiber optic cable, flat cables, etc. for length.
NO DETECTABLE LEAKAGE THRU CONDUCTOR OR INSULATION.

Wire Conductor Gage (AWG)	O. D.	Amperage Rating	Nominal Insulation Overall	Nominal Insulation Diameter (O.D.)
30	.30 mm	2	.03	0.8 mm
28	.40	2	.04	1.0
26	.50	3	.05	1.3
24	.60	3	.06	1.75
22	.78	4	.06	1.5
20	.90	6	.07	1.9
18	1.21	8	.08	2.0
16	1.50	10	.09	2.3
14	1.85	18	.11	2.8
12	2.4	25	.12	3.0
10	2.94	40	.21	5.3
6	4.67	80	.26	6.6

PAVE-Seal Epoxy Comparative Tracking Index

Tracking Index (V)	PLC
600 or greater	0
400 thru 599	1
250 thru 399	2
175 thru 249	3
100 thru 174	4
<100

The CTI value is used for electrical safety assessment of electrical apparatus, as for instance carried out by Underwriters Laboratory. The minimum required creepage distances over an insulating material between electrically conducting parts in apparatus, especially between parts with a high voltage and parts that can be touched by human users, is dependent on the insulators CTI value. Also for internal distances in an apparatus by maintaining CTI based distances, the risk of fire is reduced. Performance Level Categories (PLC) were introduced to avoid excessive implied precision and bias. — CTI Test Results

Hermetic Electrical Feedthroughs & Hermetic Sealed Connectors