Sapphire-to-Metal Brazing
Hermetic sealing of sapphire windows to metal housings for optical, pressure, and harsh-environment applications across aerospace, medical, and defense sectors.
Hermetic Optical Integration with Extreme Durability
Advanced Hermetic Solutions offers sapphire-to-metal brazing services for optoelectronic assemblies and high-pressure viewports. Our processes maintain the mechanical integrity and optical clarity of single-crystal sapphire, while enabling robust, leak-tight interfaces with metals like Kovar®, titanium, and stainless steel.
- Transparent hermetic barriers with ultra-high pressure resistance
- Active brazing or metallization for strong ceramic-metal adhesion
- Thermal cycling compatibility and low-outgassing for space and vacuum applications
- Leak testing with helium mass spectrometry (10⁻⁹ atm·cc/sec)
- Support for flat, domed, and custom sapphire geometries
With decades of brazing experience, AHS ensures sapphire joints meet mechanical, optical, and hermetic performance criteria for your most demanding use cases.
Optical & Mechanical Design Considerations
- Material Matching: Use metals with close CTE to sapphire (e.g., Kovar or Ti) to minimize thermal stress during and after brazing.
- Window Alignment: Maintain concentricity and edge clearance tolerances for flatness and optical path integrity.
- Coatings: Anti-reflective or conductive coatings may be applied post-braze depending on application.
- Edge Chamfers: Beveling sapphire edges reduces stress concentration and improves mechanical robustness during sealing.
- Dome Geometries: Curved sapphire surfaces can be brazed with proper fixture design and uniform heating profiles.
Trusted in High-Stakes Applications
- Aerospace: Optical ports for laser rangefinding, navigation, and propulsion viewing
- Defense: Pressure-sealed IR viewports for targeting and surveillance systems
- Medical Devices: Transparent seals for in-body diagnostics and sterilizable assemblies
- Industrial: Furnace windows, plasma chamber access, and sensor housings
- Scientific Research: Optical instrumentation for high-vacuum and cryogenic systems
Let's Build Your Sapphire Assembly
Partner with AHS for hermetically sealed sapphire-to-metal assemblies engineered for long-term optical, mechanical, and thermal performance.
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