About Us

With extensive expertise in ceramic-to-metal sealing technology, we provide design support across a range of critical areas, from optimising geometries and tolerances to selecting the most appropriate materials and braze alloys.

Our approach is underpinned by Design for Manufacture (DFM) principles, ensuring every design is not only technically robust but also efficient, practical, and ready for reliable production.

We use industry-leading Autodesk Inventor and AutoCAD software, enabling advanced design capabilities and the creation of high-quality, fully detailed design packs. These ensure accuracy and consistency throughout every stage of production.

For major design projects, we implement comprehensive design control documentation tailored to each component or assembly, in line with the stringent requirements of AS9100. This structured approach ensures all design and test data is traceable and retained, helping to support continuous improvement and future refinement of both process and product.

Seamless manufacturing begins with effective procurement. A carefully vetted supplier base, combined with strict control over specifications and drawing management, helps minimise the risk of downstream issues. We’ve spent decades refining our supply chain and processes, prioritising in-house manufacturing wherever possible to maintain full control over quality, traceability, and the handling of critical components.

We operate several precision cleaning processes to ensure component cleanliness throughout production. Our primary method uses a fully enclosed perchloroethylene degreasing plant, supported by a secondary system to provide full redundancy and maintain production during maintenance or downtime.

In addition to chemical and solvent-based cleaning, we also operate abrasive cleaning facilities, with multiple blast cabinets using pure alumina beads to avoid surface contamination. Maintaining consistent cleanliness is critical to achieving high product yield and preserving the integrity of subsequent processing steps.

We use our own proprietary metallization paints, formulated from a precise blend of refractory metals and binders, all made in-house from raw materials. This mixture is applied to the ceramic surface, by means of spraying, brushing, or screen printing, before being sintered to create a robust, adherent metal layer suitable for subsequent bonding processes.

Sintering is a critical step in the metallisation process. It enables the necessary chemical bond to form between the refractory metals and the ceramic substrate. We operate several dedicated metallizing kilns, sinter ceramics and sapphires at temperatures exceeding 1500°C and 1700°C respectively. All sintering is carried out under carefully controlled atmospheric conditions to ensure consistent metallisation quality, adhesion strength, and repeatable product performance.

We operate a dedicated in-house nickel plating line, carefully controlled and maintained to ensure consistent surface quality and reliable plating adhesion. With this capability, we maintain full process control and ensure each component meets our exacting standards.

For metallized ceramic and sapphire, once the metallised layer is sintered, they undergo a thin nickel plating process. This nickel layer provides a suitable surface for braze alloy wetting and is an essential step to ensure effective wetting.

Nickel plating of metal components is also a common and important part of the process. Depending on the metal substrate, nickel plating can significantly enhance braze wetting and allow capillary action to work more effectively, ensuring the filler material penetrates the full length of the joint for a complete, reliable bond.

Brazing is a critical stage in our manufacturing process and is selected based on both the materials involved and the performance requirements of the final assembly. The most appropriate method depends on the braze alloy and the combination of materials within the seal.

Vacuum Brazing: This process is carried out under high vacuum conditions, with leak rates below
1 × 10⁻⁹ mbar l/s. Vacuum brazing is particularly well suited for substrates such as stainless steel, where reducing atmospheres are not appropriate. For more reactive materials like commercially pure titanium, very clean vacuum conditions at elevated temperatures are essential. These conditions prevent oxygen absorption, which can hinder wetting and result in poor joint quality. We operate two vacuum furnaces with maximum working envelopes of approximately Ø280mm x 400mm length.

Reducing Atmosphere Brazing: This is the most commonly used brazing method for ceramic to Alloy 42 assemblies. The process is carried out using one hundred percent pure hydrogen gas. Dew point levels are automatically monitored to ensure a clean and effective reducing environment throughout the cycle. Our continuous belt furnace is ideal for reliable, high-volume production while maintaining strict process control and repeatability.

Inert Atmosphere Brazing: In some cases, vacuum brazing may not be suitable. For these applications, brazing is performed in a controlled atmosphere of pure argon at partial pressure. This approach enables clean and effective joints in assemblies where oxidation must be avoided but vacuum conditions are either unnecessary or impractical.

Soldering: Soldering is used for assemblies that require lower temperature joining. This process is typically performed in air and uses our external ceramic heater system, which applies localised heat to the joint area only. This targeted approach reduces thermal stress on the assembly and ensures precise control during soldering.

We offer in-house welding capabilities, including precision TIG welding using high-purity shielding gases to ensure clean, reliable joints. For applications requiring exceptionally refined welds or where significant differences in coefficient of thermal expansion (CTE) exist between materials, we also provide electron beam (EB) welding.

Inspection is carried out at every stage of production to ensure complete process control and product conformity. We employ Helium leak testing, X-ray examination, electrical testing and visual inspection under magnification to verify process and product quality throughout. Further details on our inspection methods can be found below.

Visual inspection is carried out at every stage of production, including final inspection, to ensure early identification of defects and prevent process errors. Our trained inspectors use up to 63x magnification as standard, checking for cracking, voids, contamination, and surface inconsistencies across all components.

To guarantee hermetic integrity, we conduct helium leak testing in-house throughout all stages of production. This highly sensitive test method ensures leak rates are within ultra-high vacuum specifications, typically below 1 × 10⁻¹² mbar l/s.

We validate electrical integrity using in-house dielectric and insulation resistance testing. Dielectric strength testing is performed up to 30kV DC, ensuring no breakdown occurs under voltage. Insulation resistance is measured up to 10¹³ Ohms. For more advanced electrical requirements, approved subcontractors are engaged.

Our Fischerscope XDLM-237 enables precise, non-destructive measurement of metallization and plating thicknesses. Used throughout production, it ensures correct paint deposition and plating uniformity, helping maintain strict process control and consistent performance across batches.

We conduct hydrostatic and inert gas pressure testing in-house up to 400 bar, verifying structural integrity for pressure-rated applications. Testing is performed under controlled conditions for either validation, development, or proof-of-concept testing where specified.

For detailed inspection of joint interfaces, we offer full sectioning, potting, and polishing capabilities. This is particularly useful during development stages, allowing analysis of braze joint penetration and interface quality where complex material combinations are used.

Tensile testing is used to qualify the mechanical bond strength between the metallized ceramic surface and attached metal components. This provides assurance of mechanical durability and long-term performance under service loads.

Thermal shock and expansion stress testing is performed in-house, including air cycling to ~600°C or thermal swings down to cryogenic temperatures (e.g. liquid nitrogen). For more complex or extended thermal profiles, testing is subcontracted to our trusted test house.

All ceramics undergo dye penetrant inspection prior to production to identify micro-cracking. For critical applications, CT inspection of braze joints can be arranged via our approved test house, providing internal flaw detection (voids) without damaging the assembly.

Using our in-house Mitutoyo Crysta-Apex V coordinate measuring machine (CMM), we conduct highly accurate dimensional inspections of both individual components and assembled parts. This allows us to validate complex geometries, ensure critical tolerances are met, and maintain traceability across production. The system is especially tight-tolerance parts, and first article inspection reports.

We utilise EFACS E/8 as the backbone of our operational and manufacturing systems. This powerful ERP platform supports everything from production planning and material requirements to quality control, order processing, and traceability. Its integrated production planning and MRP tools allow us to efficiently manage both make-to-order and make-to-stock operations, ensuring timely delivery and optimal material use.

Crucially, EFACS supports our AS9100-compliant quality management processes by maintaining in-process controls, document versioning, and audit trails. Moreover, customisable workflow automation helps streamline internal approvals, purchase ordering, and task notifications, ensuring consistent execution of business-critical processes.

When applicable, Works Orders reference internal documentation, including:

• SPS (Standard Process Sheet)
• IMS (Inspection Method Sheet)
• PSS (Purchasing Specification Sheet)
• WPS (Weld Procedure Sheet)
• APS (Administrative Procedure Sheet)

These define approved methods for production and inspection. Operators are required to read and sign off procedures, while training matrices track skill levels and ongoing competency.

New or modified designs undergo internal approval using our Engineering Change Order (ECO) system, fully integrated with Autodesk Vault for engineering control. For customer-specific projects, we employ a DAF (Drawing Approval Form) process, ensuring client approval is obtained before final release to manufacture.

Certificates of Conformance are provided on request, typically covering vacuum integrity and dimensional compliance as standard. Material certificates can also be included, ensuring full traceability and quality assurance.

We offer First Article Inspection (FAI) on new or modified parts, documenting and validating key characteristics such as dimensions, materials, electrical, and vacuum performance. FAI ensures assemblies meet requirements before entering regular production.