Kovar Machining Services

DEK's Kovar machining services deliver CNC milled and turned Kovar parts from a single prototype to production, with no MOQ. Seal-critical faces are finished for glass-to-metal and ceramic-to-metal seals and checked on CMM.

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±0.003mm
Pins under 10 mm
3 days
Fastest prototype
1000 mm
Kovar A bar length

ISO 9001:2015 Certified AS9100D and ISO 13485 certified

Why Kovar Machining Demands a Specialized Process

Kovar is specified because its coefficient of thermal expansion tracks borosilicate glass and certain ceramics. Kovar machining therefore has to hold dimensional control tight enough that a downstream seal will not crack under thermal cycling, which is why DEK runs it as precision machining work.

The alloy work-hardens fast under standard steel-cutting parameters, so programs are adjusted to protect tooling and finish. Every order follows a documented sequence, from incoming material inspection to first article approval and outgoing inspection, under our certified quality system.

No MOQ, one process from prototype to production
Prototype Kovar parts in as fast as 3 days
In-house CMM with complete lot traceability
ISO 9001, ISO 13485 and AS9100D certified

Kovar Grades and Stock We Machine

DEK stocks Kovar A, the standard glass-sealing grade, as bar and plate so most orders start without a raw-material wait.

Kovar A
ASTM F15, UNS K94610
The standard glass-sealing grade, chosen when a part must match borosilicate glass or ceramics through repeated temperature swings.
Kovar A round bar
Up to 1000 mm long
Turned into micro pins, header pins and feedthrough shafts under 10 mm, plus connector bodies and shells.
Plate
Standard mill thicknesses
Kovar A plate milled into IC package lids, sensor and housings up to roughly 1000 mm overall.

±0.003 mm
Turned features under 10 mm
±0.005 mm
Seal flanges and mating bores
±0.01 mm
5-axis contoured housings
Ra 0.4–0.8
µm on seal-critical faces

Our Kovar Machining Capabilities

Rigid workholding, conservative chip loads and active tool-wear monitoring keep Kovar's work-hardening from degrading a finish mid-run.

1

CNC Milling

CNC milling on 3-, 4- and 5-axis machines; contoured lids and housings with 5-axis profile control hold ±0.01 mm.
2

CNC & Swiss Turning

CNC turning, including Swiss-type turning for small, high-precision header pins and feedthrough shafts held to ±0.003 mm.
3

EDM (Wire and Sinker)

Wire and sinker EDM for Kovar features that are better cut without tool pressure on a work-hardening alloy.
4

Precision Grinding

Precision grinding brings seal-critical faces to Ra 0.4–0.8 µm (16–32 µin) on flanges, lid rims and mating bores.

What Makes Kovar Machining Different

Key factors our engineers evaluate before a Kovar part reaches a glass-to-metal or ceramic-to-metal seal.

1

Fast Work Hardening

Kovar work-hardens faster than most stainless grades, so standard steel-cutting parameters chew through tooling. Programs use conservative chip loads and sharp tooling.
2

Thermal Expansion Match

Its expansion tracks borosilicate glass and certain ceramics. Dimensional control must be tight enough that the downstream seal will not crack under thermal cycling.
3

Oxide Control Before Sealing

Sealing parts typically need hydrogen firing and vacuum annealing. DEK coordinates this through qualified partner furnaces and finishes ground and plated geometry to spec ahead of it.
4

Stable Setup, Prototype to Run

Rigid workholding and active tool-wear monitoring carry a job from first-off prototype into repeat production without re-qualifying the process when volume changes.

When to Choose Kovar vs Invar or Stainless Steel

Kovar suits glass- and ceramic-matched seals; check the alternatives before locking a spec. See all controlled-expansion alloys we machine.

Criteria	This MaterialKovar	Invar	Stainless steel
Choose it for	Glass/ceramic seals	Tooling, instruments	Non-hermetic parts
Thermal expansion	Matches borosilicate	Near-zero	–
Work hardening	Faster	–	Slower than Kovar
Hermetic seal	Yes	–	Not needed
Cost	Higher than steel	May cost less	May cost less

Industries Using Machined Kovar Components

Anywhere a metal-to-glass or metal-to-ceramic joint has to survive repeated temperature swings without cracking.

CNC Machined Kovar Parts with Finishing

Kovar parts are machined and finished in one order, with plated surfaces prepared for downstream sealing steps.

Surface Finishing

Electroplating
Electroless nickel plating
Passivation

Need another finish or a firing step? Ask our engineers

Kovar Machining Services FAQ

Common questions on cost, tolerances and lead time for machined Kovar parts.

How much do Kovar machining services cost?

Kovar costs more per kilogram than steel and cuts slower because it work-hardens, so cycle time and tool wear weigh more than on a comparable stainless part. Plating, hydrogen firing and vacuum annealing are quoted alongside machining. An engineer returns a manually reviewed quote within 6 hours for most parts; there is no MOQ.

What tolerances can you hold on machined Kovar parts?

Turned features under 10 mm hold ±0.003 mm; seal flanges, lid rims, mating bores and standard features hold ±0.005 mm; 5-axis contoured lids and housings hold ±0.01 mm. Seal-critical faces are ground to Ra 0.4–0.8 µm. Every part is checked on in-house CMM under ISO 9001, ISO 13485 and AS9100D.

How long does Kovar machining take?

Prototype Kovar parts ship in as fast as 3 days, with 3–5 days typical for a single piece or small qualification batch. Production lead time depends on quantity, feature complexity and whether plating or annealing is in scope, and is confirmed at quoting. Kovar A bar and plate are stocked.

Is Kovar machining different from machining stainless steel?

Yes. Kovar work-hardens faster than most stainless grades, so DEK runs conservative chip loads, rigid workholding, sharp tooling and tool-wear monitoring. Kovar is chosen for its expansion match to borosilicate glass and ceramics, not corrosion resistance; without a hermetic seal, stainless or Invar may cost less.