Douglas Electrical Components designs and manufactures hermetic electrical feedthroughs and connectors for the automotive industry, supporting everything from R&D to high-volume production. As vehicles become more advanced and connected, these solutions protect critical electrical systems from moisture, chemicals, vibration, and pressure.

Its sealing technology creates durable, chemically compatible barriers across applications. In LiDAR systems, feedthroughs prevent water intrusion that can fog lenses or cause failures, while in fuel pumps they ensure long-term reliability in harsh in-tank environments. The company can also upgrade standard automotive and off-road connectors to meet demanding environmental requirements.

Multiple sealing methods are available to meet specific needs. Direct epoxy casting enables lightweight, low-profile hermetic assemblies, while backpotting allows non-hermetic connectors to be sealed with options for pins, sockets, wires, cables, and optical fibers. Solutions support internal combustion engines as well as electric, hybrid, and hydrogen-powered vehicles.

Additional options include radial O-ring feedthroughs for vacuum and high-pressure environments, along with custom metal and threaded designs. A key application is battery immersion cooling, where hermetic feedthroughs safely pass wires and conductors into dielectric fluids using chemically inert epoxy seals that are helium leak-tested for integrity beyond standard IP ratings.

Key benefits include high reliability, design flexibility, reduced component complexity, and compatibility with oils and refrigerants. Applications range from refrigerant sensors and sealed components exposed to wash-down conditions to in-tank pump systems, alternative fuel tanks, battery technologies, and high-voltage contactors.