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What We Do.

Hermetic Packaging

Glass to Metal Sealing

Ceramic Seals

Custom Machining vs. Tooling

Microwave Packages

Fiber-Optic Packages

Power & Hybrid Packages

Optical Windows


Hermetic Packaging

The term "Hermetically Sealed" is derived from Greek-Egyptian mythology, with Hermes Trismegistus magically sealing treasure chests to keep them impervious to entry. Today, Sinclair's hermetic packages keep your sensitive electronic devices protected from the harsh environments of space, atmosphere, and sea depths.

Creating reliable hermetic seals in today's custom-machined exotic material packages can be as much art as it is science. Is it magic? No, we're just very good at what we do.
Sinclair has been producing high quality parts since 1946. Whether you need a Power or Hybrid Package, Microwave or Fiber-Optic Package, Optical Windows, Connectors or Feedthrus, call upon Sinclair to be your source - today and tomorrow.


Glass-to-Metal Sealing

Glass-to-metal sealing involves the process of bonding glass & metal to create a hermetic seal, allowing isolated electrical current through a metal wire from outside of the metal package to the inside, without compromising the environment inside. The sensitive electronic components housed inside the package remain protected from the harsh environment outside, receiving current through the isolated wires only. Optical-quality glass can also be used to transmit visible & non-visible wavelengths of light to optical sensors inside the metal package.

There are a number of ways to produce the glass-to-metal seal, but essentially it involves melting the glass & bonding it to the metal parts through a high-temperature furnace with a controlled atmospheric environment. Oxides may or may not be used, depending on the package materials & proposed use of the hermetic package.

Glass with thermal expansion properties similar to the metals they are bonded to create a Matched Seal, while glass with thermal expansion properties different from their metals can create a Compression Seal.

Machined Microwave or Fiber-Optic Packages & drawn tub Hybrid Packages made from nickel-iron-cobalt alloys like Kovar & nickel-iron alloys like 46 Alloy tend to use Matched glass seals, while lower-cost steel frame Power Packages & Headers may use Compression seals. A glass sealed Feedthru can also be brazed into a package, rather than making a direct glass-to-metal seal.


Ceramic Seals

Ceramic to metal seals accomplish the same thing as glass seals do, but certain designs, materials, & work environments lend themselves better to using ceramic than glass. Ceramic insulators are metalized and brazed to the metal package to produce a hermetic seal.

High-Reliability custom-machined Microwave Packages, Fiber-Optic Packages, or high-end Hybrid & Power Packages may have ceramic seals instead of glass, or they may employ the use of brazed-in feedthrus & multi-pin connectors using ceramic or glass.


Custom Machining vs. Tooling

CNC Machining has revolutionized the production of hermetic packages, but there are trade-offs vs. the creation of hard tooling. Tooling can allow for a lower cost part that's easily stamped out in large production runs, but making a design change to a part produced off tooling may cause production delays as the tools are modified.

CNC Machining allows for more complex designs than tooling can typically produce, and changes require re-programming the code used to control the computer-controlled machining equipment. Turn-around time from quote to production of first prototype pieces is much faster with CNC equipment, and tighter tolerances are achievable as well. Machining exotic metals & alloys require experience with the nuances of each type of material.

Metal Injection Molding (MIM) parts are also something Sinclair can use to produce your hermetic package. Contact Sinclair for more information on what may be the best options for creating your packages.


Microwave Packages

Sinclair's Microwave Packages focus on creating a glass-to-metal seal with a 50-Ohm resistance. Glass & Wire diameters & material types are chosen to create this resistance level. Sinclair can manufacture virtually any custom machined configuration in a variety of materials & feedthru options.

Microwave Packages may be configured with Direct Glass-to-metal seals, Ceramic-to-metal seals, Stripline Ceramic Feedthrus, SMA, SSMA, OSP, OSSP, and OSM Interfaces; Bulkhead DC, Micro-D, or Push-On Connectors. Kovar, Titanium, Aluminum, and other materials may be used for the machined housings. Post-Electroplate Machining is also available.

In addition to completely custom configurations, Sinclair offers open-tooling for all standard Drop-In Microwave Packages, including Bolt Channels, Pill Packages, and Rectangular 2,3, & 5 pin .246" wide Microwave Packages.


Fiber-Optic Packages

Custom FIber-Optic Packages for Telecommunications use are typically machined from Kovar or other nickel-iron alloys, and employ a number of different Fiber Entry methods. Fiber tubes can be machined directly as an integrated part of the housing, or a more simple drawn or machined tube may be brazed in. The connectors listed in Microwave Packages also apply to Fiber-Optic Packages. Whatever your requirements, Sinclair can meet your Fiber-Optic Package needs.


Power & Hybrid Packages

Sinclair's Power Packages typically employ the use of a copper-cored nickel-iron alloy wire to allow for higher-current requirements in a Glass-to-metal seal hermetic package. Ceramic seals may be used to accomodate a completely copper or Glidcop wire for even higher electrical currents. High-Conductivity base materials such as Copper, Copper-Tungsten, & Giidcop are also used for greater heat dissipations. Standard sizes such as JEDEC TO-254, TO-257, TO-258, TO-259, TO-265, MO-078, MO-079 are available with Open Tooling. Custom options are also available on all Power Packages.

Hybrid Packages are typically made from Kovar or other nickel-iron alloys, usually have Matched glass seals with Kovar pins, and may be made from one-piece drawn tub bodies, multi-piece frame / base components, or can be custom machined. Sinclair has a very large inventory of standard tools for Hybrid Packages. Contact us to discuss your design needs today.


Optical Windows

Optical Windows keep components safe from outside environments while allowing optical transmission to a sensor inside the metal shell or housing. Optical materials include Borosilicate Glass for use with Kovar, or Soda Lime Glass for use with Stainless Steel. UV, Sapphire, Quartz, and special Filter Glasses are also available depending on what the optical transmission needs are.

Sinclair uses our own proprietary sealing process which allows the surface of the window glass at the aperture to retain a flatness criteria that is unsurpassed in the industry. Our windows are capable of meeting the most stringent requirements, for Space applications, Medical, Military, or Undersea use.


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