Hermeticity of vacuum edge-sealing materials are one of the paramount requirements, specifically, to the evolution of energy-efficient smart windows and solar thermal evacuated flat plate collectors. This study reports the design, construction and performance of high-vacuum glazing fabrication system and vacuum insulated glazing (VIG). Experimental and theoretical investigations for the development of vacuum edgeseal made of Sn-Pb-Zn-Sb-AlTiSiCu composite in the proportion ratio of 56:39:3:1:1 by % (CS-186) are presented. Experimental investigations of the seven constructed VIG samples, each of size 300 mm·300 mm·4 mm, showed that increasing the hot-plate surface temperatures improved the cavity vacuum pressure whilst expediting the pump-out hole sealing process but also increases temperature induced stresses. Successful pump-out hole sealing process of VIG attained at the hot-plate set point temperature of 50 °C and the approximate cavity pressure of 0.042 Pa was achieved. An experimentally and theoretically validated finite volume model (FVM) was utilised. The centre-of-pane and total thermal transmittance values are calculated to be 0.91 Wm−2K−1 and 1.05 Wm−2K−1, respectively for the VIG. FVM results predicted that by reducing the width of vacuum edge seal and emissivity of coatings the thermal performance of the VIG is improved.