Custom-engineered, hermetically sealed electrical wire and fiber optic cable feedthroughs that maintain a hermetic seal under low & high pressure, vacuum, and temperature ranges between −200°C to 200°C. Pave Technology’s hermetic connectors are designed and manufactured to your exact specifications!
A hermetic electrical feedthrough, also called a hermetic wire feedthrough or electrical feedthrough pressure seal, is a sealed passthrough assembly that carries electrical conductors through a pressure or vacuum barrier without any gas or fluid leakage.
PAVE’s hermetic feedthroughs use a proprietary epoxy formulation that seals through the wire insulation and including any stranded or shielded conductors, completely eliminating the unreliable pin connections required by glass-to-metal or ceramic hermetic connectors. There is no leakage through the wire insulation, conductors, or any shielding in either pressure direction.
Available from 1 to 100+ wires, #2 AWG to #36 AWG, and virtually any insulation type (PTFE, ETFE, PVC, and others). Bulkhead Mountable via NPT thread, face seal O-ring, Conflat/KF flanges, or custom bulkhead configurations. We have signal, power, thermocouple, coaxial RF, high voltage and fiber optic standard or custom versions to choose from.
Applications include thermal vacuum chambers, subsea connectors, pressure vessels, cryogenic systems, aerospace flight hardware, industrial process equipment, fuel systems, hydraulic systems, subsea systems and anywhere a certified liquid or gas-tight seal is required.
— Core engineering philosophy, PAVE Technology Co.
PAVE epoxy bonds to the wire insulation and conductors, sealing through the wire itself, not just around it. No leakage through insulation, stranding, or shielding. Seal holds bi-directionally.
Unlike glass-to-metal or ceramic hermetic designs, PAVE feedthroughs require no soldering of wires to pins on either side, dramatically reducing labor costs and potential failure points.
Custom wire counts, gauge, insulation type, bulkhead configuration (NPT, O-ring face seal, KF/Conflat flange, custom), and pressure rating—all designed to your exact application requirements.
Vacuum feedthroughs rated to 10⁻⁸ Torr; subsea versions certified to 10,000+ psi for deep water applications. PAVE seals gases, fluids, and steam across a wide range of process environments.
Technical sales engineering is one email or phone call away. In-stock Quick Ship designs are available for same-day order placement. Credit cards accepted.
All specifications apply to PAVE’s proprietary hermetic seals unless otherwise noted. Contact us for application-specific confirmation.
| Property | Value / Rating | Condition / Notes |
|---|---|---|
| Dielectric Strength | > 17.4 kV/mm | Per ASTM D149 |
| Dielectric Constant | 5.3 | @ 1 MHz |
| Volume Resistivity | 1 × 1015 Ω·cm | @ 125°C |
| Dissipation Factor | 0.03 | @ 1 MHz |
| Hardness (Shore D) | 96 | Fully cured |
| NASA MAPTIS Toxicity | Rating K | Space-grade qualification |
| Odor Rating | Rating A | NASA MAPTIS |
| Thermal Vacuum Stability | Rating A | NASA MAPTIS |
| Flammability | FM Class 3600 | EExd II 90°C T1 |
| Temperature Range (150 Grade) | −200°C to +125°C | PAVE Wire Seal® 150 |
| Temperature Range (200 Grade) | −200°C to +150°C | PAVE Wire Seal® 200 |
| Temperature Range (200 UL94V-0) | −200°C to +200°C | PAVE Wire Seal® 200 UL94V-0 |
| Standard Pressure Test | 80 psi (5.5 bar) | Air/nitrogen, no bubbles visible |
| Standard Vacuum Test | High-vac helium | 10−8 cc/sec or less |
| Max Pressure Available | 10,000+ psi (650+ bar) | Select designs, confirm with factory |
| Helium Leak Test (optional) | 4 × 10−9 cc/sec | Available on request |
| Vacuum Rating | 10−8 Torr | Low and high vacuum |
| RoHS Compliance | Compliant | All product lines |
| ISO Certification | ISO 9001:2015 | Expires November 2028 |
| High Vacuum Expoxy Outgassing Approval Rate | 0.20% TML / 0.01% CCCM / 0.08% WVR | Meets NASA’s Outgassing Standard |
PAVE maintains full ISO 9001:2015 certification, ensuring every hermetic feedthrough and connector is manufactured and inspected under a rigorous, documented quality management system.
Helium mass spectrometry leak testing is available upon request on most designs. Standard factory test: 80 psi air/nitrogen with no visible bubble—or high-vacuum N2 leak testing upon request.
Most PAVE hermetic seal product lines comply with RoHS (Restriction of Hazardous Substances) and REACH directives. Full compliance documentation available upon request for restricted materials sourcing requirements.
Every PAVE product is engineered for gas-tight, moisture-proof performance in pressure, vacuum, and extreme-temperature environments.
1–100+ wires, #4–#30 AWG, any insulation, any bulkhead style. The core PAVE hermetic electrical feedthrough line.
Double-ended hermetic connectors with mating plugs on both sides, 2–128 contacts. USB, RJ45/Ethernet, and some with IP68 options.
Single-sided hermetic circular connectors with pre-wired leads or solder cups. Gold or silver-plated contacts.
Standard, high-density, micro, and nano D-Sub hermetic connectors. 9 to 200+ pins, single or dual-sided configurations.
Hermetically sealed coaxial and shielded cable feedthroughs for low & high-frequency signal applications in vacuum and pressure environments.
Bi-metallic thermocouple wire feedthroughs sealed through the bulkhead. Type J, K, T, E, N, and others. No signal loss through the seal.
Hermetically sealed fiber optic feedthroughs for single-mode and multi-mode fiber in vacuum, pressure, and harsh environment applications.
Specially engineered hermetic feedthroughs for high-voltage cable and wire pass-throughs in pressure and vacuum environments.
Single-conductor terminal and stud-style hermetic seals for high-current power feedthroughs through pressure or vacuum barriers.
Solder cup pin seal feedthroughs for PCB and panel mounting in hermetically sealed enclosures and pressure housings.
Hermetic feedthroughs for flat ribbon cable and flex PCB pass-throughs through walls, bulkheads, and vacuum chambers.
UL 1203 & ULS940V-O listed explosion-proof line bushings for wire feedthroughs through explosion-proof enclosures in hazardous locations.
PAVE stocks a wide range of hermetic feedthrough seals, hermetic wires, pin connectors and terminal seals for immediate order placement. Most in-stock designs can be leak tested and certified to significantly higher pressures than standard drawings indicate. Rush shipments for custom manufacturing. Credit cards accepted.
A hermetic electrical feedthrough provides a certified gas-tight and liquid-tight seal while allowing electrical conductors to pass through a pressure or vacuum boundary. Unlike a standard cable gland, which seals around the outside of a cable, PAVE-Seal® feedthroughs seal through the wire insulation and individual conductors. This eliminates leakage paths and protects critical systems from gas or fluid ingress or egress. PAVE products replace many traditional glass or ceramic hermetic seals!
Yes. All PAVE hermetic feedthroughs are designed to seal pressure or vacuum in both directions. For applications above 500 psi (30 bar), additional design and installation requirements may apply. Some high-pressure models must be installed in a specific orientation, so be sure to specify pressure direction when ordering.
No. PAVE-Seal® wire feedthroughs and PAVE-Mate® pin connectors provide the same leak-tight performance. Both use PAVE’s proprietary hermetic epoxy seal and are tested to the same helium leak standards.
PAVE can hermetically seal virtually any wire or cable type, including PTFE (Teflon), ETFE (Tefzel), PVC, polyimide (Kapton), silicone, rubber, and others. Wire gauges from #4 AWG to #30 AWG with 1 to 500+ conductors per assembly. Coaxial cables, thermocouple pairs, shielded cables, and flat ribbon cables are also supported.
If you have a specific wire type or specification, contact PAVE engineering to confirm compatibility.
Yes. All PAVE epoxy grades are rated to -200°C. Cryogenic applications may require PTFE O-rings and specialized configurations. Let us know your operating conditions so we can recommend the appropriate design.
PAVE offers multiple paths to ordering. For in-stock Quick Ship designs, call +1 (937) 890-1100 (ext. 103 for technical sales, ext. 102 to place an order) or email help@pavetechnologyco.com.
For custom designs, submit a Quote & Engineering Design Assistance Request with your wire count, gauge, insulation type, bulkhead style, pressure or vacuum rating, and temperature range. A PAVE engineer will respond with a rapid-turnaround quote. Credit cards are accepted on all orders.
From aerospace to defense, our hermetic feedthroughs are engineered to seal and perform under the most demanding conditions.
Let’s build yours.
