Pressure-rated, leak-tight sensor enclosures with precision sealing surfaces and validated hermetic integrity for aerospace, medical, industrial, and subsea applications.
Get Hermetic Enclosure QuoteAccording to our CNC machining knowledge base, CNC machining is a computer-controlled subtractive manufacturing process that shapes materials with precision. A hermetic enclosure uses that precision to create sealing surfaces, O-ring glands, and feedthrough interfaces that prevent gas or moisture ingress. Every sealing feature—flatness, surface finish, groove depth, and feedthrough bore alignment—must be machined to tight tolerance so the enclosure can pass pressure-decay or helium leak validation.
We machine hermetic sensor enclosures from aluminum, stainless steel, titanium, Kovar, and engineering plastics, matching each material's thermal expansion and corrosion behavior to the seal type and operating environment.
Hermetic seals fail when sealing surfaces are out of flat, grooves are off-depth, or feedthrough bores are misaligned. CNC machining removes those risks by holding every critical feature to programmed dimensions and producing the smooth, plating-ready surfaces that O-rings, gaskets, and glass-to-metal seals require.
Seal lands and O-ring grooves are held within microns so compression is uniform and leak paths are eliminated.
Programmed processes ensure every enclosure copy meets the same standard—critical for validated production lots.
CNC machining eliminates mold or die lead times, enabling rapid hermetic enclosure prototypes and design iterations.
We machine aluminum, stainless steel, titanium, Kovar, PEEK, and other plastics without changing the core process.
Precision machining delivers the surface finish O-ring glands and glass-to-metal seals need for long-term leak tightness.
Multi-axis CNC machines produce intricate seal profiles, internal cavities, and feedthrough arrays in one setup.
Send your STEP or IGES file and our engineers will review seal geometry, material choice, and test strategy.
Request Free Enclosure DFM ReviewFrom O-ring sealed sensor housings to glass-to-metal feedthrough bodies, we CNC machine the enclosure geometry that keeps pressure, vacuum, and contaminants on the correct side of the seal.
Precision O-ring grooves and seal lands for IP67/IP68-rated sensor housings. Our knowledge base notes that IPx7 protects against 1-meter immersion for 30 minutes, while IPx8 supports continuous immersion at a specified depth.
Quote O-Ring EnclosureKovar and stainless steel bodies machined to match borosilicate glass or ceramics for permanent hermetic electrical feedthroughs. According to our knowledge base, Kovar's low CTE (4.6–5.4 ppm/°C) makes it essential for these seals.
Quote Feedthrough BodyEnclosures with integral M12, M8, or custom threaded ports, sealed with precision-machined threads and gland geometry for pressure sensors and transmitters.
Quote Threaded HousingBulkhead-mounted housings with sealing flanges, bolt circles, and O-ring glands for gas analyzers, flow meters, and environmental monitors.
Quote Flanged EnclosurePressure-balanced or deep-rated housings machined from marine-grade aluminum, stainless steel, or titanium with continuous seal joints and corrosion-resistant finishes.
Quote Subsea EnclosureBiocompatible titanium and stainless steel enclosures with hermetic laser-weld preparation and bio-compatible surface finishes for implantable sensors.
Quote Medical EnclosureLightweight aluminum 7075-T6 hermetic enclosures with bead-blasted and anodized Type II finishes for avionics and satellite electronics—similar to the aerospace enclosure case study in our knowledge base.
Quote Aerospace EnclosureMulti-cavity housings, adapter plates, and hybrid enclosures that bridge standard sensor footprints with custom sealing interfaces.
Quote Custom EnclosurePrecision-machined cover plates with flat sealing faces, counterbores, and alignment features that complete the hermetic assembly.
Quote Hermetic LidUpload STEP or IGES and receive a detailed quote covering seal geometry, material, finish, and leak-test strategy.
Upload Enclosure CADThe material choice for a hermetic enclosure controls thermal expansion matching, corrosion resistance, weight, and seal compatibility. We machine the metals and plastics best suited to each application.
Lightweight, corrosion-resistant housings with excellent anodizing response for aerospace and industrial sensors.
Corrosion-resistant, high-strength enclosures for chemical, medical, and pressure-rated sensor applications.
High strength-to-weight ratio and biocompatibility for implantable, marine, and aerospace hermetic enclosures.
Nickel-iron-cobalt controlled-expansion alloy for glass-to-metal and ceramic-to-metal hermetic feedthroughs.
High-performance insulators, retainers, and lightweight housings for non-conductive hermetic assemblies.
High-temperature, corrosion-resistant superalloys for extreme chemical and downhole sensor environments.
Our engineers match CTE, corrosion resistance, and weight to your hermetic enclosure's environment and validation requirements.
View Material Guide Ask an Enclosure EngineerA hermetic enclosure is only as good as its sealing features. We machine each O-ring gland, seal land, feedthrough bore, and thread interface with the precision required for pressure, vacuum, and environmental protection.
Proper gland width, groove depth, and corner radii prevent over-compression and maintain consistent sealing force across temperature cycles.
Sealing faces are machined flat and smooth so O-rings and gaskets compress evenly without leak paths.
Threaded ports are machined to precise pitch diameter and class of fit for sealant, ferrule, or metal-to-metal sealing.
Bores for glass-to-metal or ceramic feedthroughs are positioned and finished to match the seal insert's diameter and CTE.
Kovar, aluminum, stainless steel, and titanium are selected so the enclosure and seal expand and contract together.
Controlled Ra on sealing surfaces improves O-ring life and supports reliable glass-to-metal and epoxy bonds.
Our engineers review groove geometry, material CTE, and finish before machining to reduce validation risk.
Submit Seal Design for ReviewThe right finish protects sealing surfaces from corrosion, galling, and environmental attack while preserving the dimensional precision needed for hermeticity. We match each finish to the enclosure material and operating environment.
Wear-resistant layer for aluminum hermetic housings
Uniform corrosion protection on internal sealing surfaces
Matte aerospace finish on 7075-T6 enclosures
Every hermetic enclosure is inspected where it matters most: seal land flatness, O-ring groove dimensions, feedthrough bore position, surface roughness, and final leak rate. We document each critical dimension and test result so your enclosure can move straight into qualification or production.
We can coordinate helium leak testing, pressure cycling, and thermal shock validation through approved partner labs.
Discuss Validation PlanEngineers review seal geometry, material CTE, and test requirements before any chips fly.
Milling, turning, and 5-axis profiling produce the enclosure body, grooves, and feedthrough features.
Anodizing, passivation, electroless nickel, or plating is applied to protect sealing surfaces.
CMM, surface roughness, pressure-decay, and helium leak testing validate hermetic integrity.
We provide first-article reports, in-process photos, and full inspection documentation with each shipment.
Request Full TraceabilityA hermetic sensor enclosure is a sealed housing that prevents gas or moisture from entering or leaving, protecting the sensor and electronics inside. CNC machining creates the precise sealing surfaces, O-ring grooves, and feedthrough bores that make this protection possible.
According to our knowledge base, IPx7 indicates protection against immersion in 1 meter of water for 30 minutes, while IPx8 indicates protection against continuous immersion at a specified depth. With proper seal design and machining, our enclosures routinely meet IP67/IP68 and can be tested to IPx9 for high-pressure washdown.
Material choice depends on the seal type and environment. Aluminum 6061-T6 and 7075-T6 are common for lightweight aerospace and industrial housings. Stainless steel 316L and 17-4PH resist corrosion in chemical and medical applications. Titanium offers strength-to-weight and biocompatibility. Kovar is essential for glass-to-metal hermetic feedthroughs due to its low CTE matching borosilicate glass and ceramics.
According to our knowledge base, Kovar is a nickel-iron-cobalt controlled-expansion alloy with a coefficient of thermal expansion of 4.6–5.4 ppm/°C at 30°C. Its low thermal conductivity and tendency to work-harden require specialized tooling, controlled cooling, and careful feeds and speeds to maintain the surface finish and dimensional accuracy needed for a reliable hermetic seal.
Standard hermetic enclosure features are held to ±0.005mm. Critical seal lands, O-ring grooves, and feedthrough bores often require ±0.001mm with surface roughness controlled for the specific seal material. Every critical dimension is verified on CMM.
Our knowledge base identifies several leak-testing methods including pressure decay, bubble testing, ultrasonic detection, and helium leak testing. We typically use pressure-decay screening for production parts and helium leak testing for the most stringent hermetic requirements.
Yes. We machine titanium and stainless steel implant-grade enclosures under our ISO 13485 quality system, with biocompatible finishes and full material traceability. Laser-weld preparation and clean-room-compatible cleaning can be coordinated.
Upload your CAD file through our contact page and include quantity, material, finish, IP or leak-rate requirement, and any feedthrough or port details. Our engineers will return a detailed quote and DFM feedback within 24 hours.
Talk directly with an applications engineer who specializes in sealed sensor housings.
Ask an Enclosure QuestionGet a production quote, enclosure DFM review, and leak-test strategy in one business day. We support prototypes, qualification runs, and high-volume production with consistent hermetic quality.
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