High Voltage Wire Feedthroughs – Hermetic Electrical Feedthroughs for Vacuum & High Pressure
PAVE-Seal® high voltage wire feedthroughs are precision-engineered hermetic electrical feedthroughs designed to safely transmit high voltage through sealed bulkheads while maintaining vacuum integrity, pressure containment, and leak-tight performance. These feedthroughs are ideal for applications requiring reliable high-voltage power transfer in vacuum chambers, pressure vessels, and harsh industrial or research environments.
Using PAVE’s proprietary hermetic epoxy sealing technology, each feedthrough delivers long-term electrical reliability with helium leak rates as low as 10⁻⁹ cc/sec (design dependent) and operating voltages tailored to customer requirements.
Request a Custom High-Voltage Feedthrough Design. Engineering support available for non-standard voltage, pressure, or temperature requirements.
Resources and Downloads
Below you will find standard high voltage wire feedthrough drawings, organized by conductor count, mounting style, and physical configuration.
What Are High Voltage Wire Feedthroughs?
High-voltage wire feedthroughs are specialized hermetic electrical feedthroughs that allow one or more insulated electrical conductors to pass through a sealed wall while safely handling elevated voltages. Unlike standard electrical passthroughs, these feedthroughs prevent electrical breakdown, corona discharge, and leakage of gases or fluids—making them essential in vacuum, high-pressure, and high-energy systems.
PAVE-Seal® high voltage wire feedthroughs are designed for bi-directional pressure and vacuum service, ensuring consistent sealing performance regardless of pressure direction.
Key Features & Performance Capabilities
- Designed for low- to high-voltage applications (custom voltage ratings available)
- Electrical insulation optimized to minimize arcing and leakage
- Suitable for DC and AC high-voltage systems
- Fully hermetic, vacuum-tight, gas-tight, and fluid-tight
- Helium leak rates to 10-9 cc/sec depending on design
- Seals remain intact even if external wire lengths are modified
- Operating temperature ranges are customizable from approximately −200°C to +200°C
- Highly resistant to chemicals, solvents, fuels, oils, and gases
- Low-outgassing materials suitable for high-vacuum environments
- Designed to seal pressure or vacuum from either direction
- Capable of handling pressures above 300 psi (20 bar) with engineering review
Typical Applications
- Vacuum chambers and UHV research systems
- High-pressure test vessels
- Semiconductor and plasma processing equipment
- Aerospace and defense systems
- Power distribution in sealed enclosures
- Scientific instrumentation and laboratory equipment
High-Voltage Wire Feedthrough Seals Specifications
- Dielectric Strength: >17.4 kV/mm
- Dielectric Constant: 5.3@ 1 Mhz
- Volume Resistivity: @ 125° C1x1015 Ohm-cm
- Dissipation Factor: 0.03 @ 1 Mhz
- Hardness, Shore D: 96
- Low Vacuum Outgassing: TML: 25% ;CVC<: .01%
- High Fungus Resistance: MIL-STD–454J/4
- Specific Gravity: @ 25° C 2.3
- Compressive Strength: >948 kg/cm2
- Compressive Modules: 7.7×104 kg/cm2
- Tensile Strength: >470 kg/cm2
- Water Absorption (24 hours): 0.03%
HERMETIC EPOXY TEMPERATURE RATING (Epoxy is proprietary and not sold separately)
The PAVE-Seal® epoxy is impervious to most oils, solvents, fuels, freons, gases, etc. Epoxy samples are available upon request for customer’s evaluation for any specific chemical compatibility.
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.