---
title: What is Hermetic Sealing? Benefits, Types, Applications, and Common Methods
description: Explore hermetic sealing compounds engineered for aerospace and electronics applications. Trusted for leak prevention, durability, and thermal resistance.
image: https://blog.gracoroberts.com/hubfs/What%20is%20Hermetic%20Sealing_%20Benefits%2c%20Types%2c%20Applications%2c%20and%20Common%20Methods.png
---
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October 30, 2026
# What is Hermetic Sealing? Benefits, Types, Applications, and Common Methods
By [GracoRoberts](https://blog.gracoroberts.com/author/gracoroberts) · 4 minute read
## What is hermetic sealing?
Hermetic sealing refers to the process of creating a completely airtight and gas-tight seal between 2 or more components. This prevents the ingress of gases, moisture or other contaminants. This type of seal is often used in a wide variety applications.
Hermetic seals are achieved using specific materials and methods that ensure the seal remains impermeable to the elements under a variety of conditions. This is often critical in industries where environmental exposure could degrade performance, such as aerospace, electronics, medical devices, and automotive applications.
## Benefits of Hermetic Sealing
Hermetic sealing provides a reliable and effective way to protect and preserve products, enhance performance, ensure safety, and comply with industry standards:
**Protection:** Protects sensitive devices from environmental hazards like moisture, dust, gases, and pressure changes. This helps minimize the need for repairs and replacements due to component failures or contamination.
**Longevity:** Increases the lifespan of devices, due to the protection benefits listed above.
**Safety:** Prevents the leakage of dangerous materials, such as toxic chemicals or high-pressure gases. May help with adherence to regulatory standards and industry best practices, ensuring product safety and quality.
## Common Applications of Hermetic Sealing
- **Electronics:** To protect sensitive components from moisture, dust, and other contaminants that can cause malfunctions.
- **Medical devices:** To ensure sterility and prevent contamination of medical equipment and pharmaceuticals.
- **Food packaging:** To maintain freshness, prevent spoilage, and extend shelf life.
- **Automotive components:** To protect electrical systems and other sensitive parts from environmental factors.
- **Aerospace:** To maintain the integrity of sealed systems and prevent leaks that could compromise performance or safety.
## Types of Hermetic Seals and Materials Used
The effectiveness of hermetic seals depends heavily on both the type of seal and the materials involved. Below are common types of hermetic seals along with the materials typically used in their construction:
- **Glass-to-Metal Seals:** This type relies on thermal expansion compatibility between glass and metal. Common materials include borosilicate or aluminosilicate glass and metals like Kovar, nickel, or stainless steel, often used in electronics and aerospace.
- **Ceramic-to-Metal Seals:** These seals use ceramics like alumina bonded to metals (e.g., titanium or Kovar) and are known for high strength and thermal stability, often used in high-pressure or high-temperature environments.
- **Epoxy Resin Seals:** A more economical option, these seals use synthetic epoxy resins to bond materials like metals, plastics, or glass. They are suitable for low-pressure applications and are common in sensors and connectors.
- **Glass-to-Glass Seals:** In this type, two pieces of glass are fused together, typically using heat. Materials include various types of technical glass, offering excellent insulation and chemical resistance, ideal for vacuum systems or laboratory equipment.
- **Metal-to-Metal Seals:** These seals rely on precision machining and compression between two metal surfaces, often using materials like copper, aluminum, or stainless steel. They are widely used in ultra-high vacuum systems and cryogenics.
- **Elastomeric Seals (with Metal Enclosure):** While not truly hermetic on their own, elastomeric seals can be housed in metal to improve hermeticity. Materials include silicone or fluorocarbon elastomers combined with metal cases, useful in applications requiring flexibility and moderate sealing performance.
## Products Used in Hermetic Sealing
Resin Formulators RF 1366 Epoxy Resin 5 gal Pail
[ Resin Formulators RF 1366 is a medium viscosity standard epoxy resin designed for potting, encapsulating and filament winding. Shop Now](https://www.gracoroberts.com/adhesives/resin-formulators-1366-epoxy-resin-5-gal-pail/)
Resin Formulators RF 6002 Epoxy Resin 1 qt Can
[](https://www.gracoroberts.com/adhesives/resin-formulators-6002-epoxy-resin-1qt/)
**Resin Formulators RF 6002 is a flowable, high temperature and excellent chemical-resistant epoxy resin which can be used for laminating, bonding and/or encapsulating a wide variety of materials.**
##### **Shop Now**
Resin Formulators RF 1158 Epoxy Resin 55 gal Drum
[](https://www.gracoroberts.com/adhesives/resin-formulators-1158-drum/)
Resin Formulators RF 1158 is a filled, pourable epoxy resin which was formulated for potting, encapsulating or casting applications. It is slightly thixotropic and will resist slumping.
##### Shop Now
## Methods of Creating a Hermetic Seal
**Electronics - potting and encapsulating:** The image shows a visual representration of potting or encapsulating to form a hermetic seal. This is the process often used in electronics and more specifically for electric vehicle batteries. The resin is poured over the electrical components to seal and protect them. In the example shown, a black color is used, this means the components underneath cannot be seen by rival companies.
**Food - canning and vacuum packing:** Food is placed in cans,
sealed with a lid, and heated to sterilize the contents. This process kills microorganisms. In vacuum packing, air is removed from a package containing food, creating a vacuum. This helps to prevent oxidation and extend shelf life.
**Medical - syringes, diagnostic devices, implantable devices:** Examples where hermetic sealing is required include ultrasound probes, endoscopes, pacemakers, defibrillators and cochlear implants. Methods used include Laser, electron beam and resistance welding, compression fittings and gaskets.
**Aerospace - avionics and spacecraft:** On a spacecraft, a hermetic seal is crucial to protect against the vacuum of space. One well-known example is the International Space Station (ISS), where hatches between modules use specialized seals (often elastomer-based) to ensure airtightness when closing the doors. Similar sealing technology is applied to space capsules like NASA's Orion, where O-rings or metal seals are critical for ensuring crew safety in space and during re-entry.
## Product Spotlight: Hermetic Sealing
Let's dive into one of our products designed for hermetic sealing. We'll discuss key features to consider when selecting the ideal product for your specific application. As an example, we will examine [Resin Formulators 5407](https://www.gracoroberts.com/adhesives/resin-formulators-5407-epoxy-resin-with-color-olive-drab-added/).
- **Two Part:** Products used to create a hermetic seal can either be one part
or two part. A two part system like this one consists of a resin and a curing agent to control cure time
- **Color:** Black to obscure viewing the compontent, olive for military color matching
- **Properties:** Match the product to your application needs. RF 5407 is intended for use for electrical applictions, especially car batteries. For this purpose, you would need a resin with excellent electrical insulation properties and high thermal conductivity
- **Curing Agent:** This resin is compatible with 6 different curing agents. These extend application options by - changing cure time, changing cure temperature, changing gel time
---
## FAQs About Hermetic Sealing
### Why is it called a hermetic seal?
The term "hermetic" originates from Hermes Trismegistus, a figure associated with ancient scientific writings. In modern usage, it refers to an airtight seal that prevents the ingress of gases, liquids, and contaminants—critical in aerospace, electronics, and defense applications.
### What materials are used in hermetic sealing?
Hermetic seals often use a combination of metals (such as stainless steel, Kovar, and copper), technical glasses (like borosilicate), ceramics (e.g., alumina), and epoxy-based compounds. Resin Formulators provides advanced epoxy formulations tailored for high-performance sealing in demanding environments.
### Is hermetic sealing used outside of aerospace and electronics?
Yes. Hermetic sealing is also applied in medical devices, sensor packaging, and food preservation. In industrial applications, epoxy-based hermetic compounds are preferred for their thermal stability, chemical resistance, and long-term durability.
### How long do hermetic seals last?
The lifespan of a hermetic seal depends on factors like material selection, application environment, and stress exposure. In aerospace or electronics, properly applied hermetic epoxy compounds can maintain performance for decades under stable conditions.
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