Linear Actuator Sizing Calculator
Estimate preliminary force, stroke and installed-length requirements before product matching. Keep the assumptions visible, then verify the result against current product data, geometry and operating conditions.
Model the mechanism first. Then size the actuator.
This calculator is an early engineering aid. It does not verify model-specific load-speed performance, duty, side load, structural strength, controls or safety conditions.
Keep gravity, resistance, acceleration and leverage visible.
Hiding all force components inside one result makes review harder. A useful sizing record shows where the requirement came from and where assumptions remain.
Gravity depends on travel direction, guide resistance should be measured where practical, and acceleration matters when the load must reach speed quickly.
The actuator must generate enough moment around the pivot. As the perpendicular moment arm becomes smaller, actuator force can rise sharply.
A small mounting change can create a large force change.
For lids, hatches, doors and levers, evaluate leverage across the motion rather than only at one convenient angle. If the line of action passes close to the hinge, the effective moment arm shrinks and required force rises.
Measure the motion, not just the payload.
For existing mechanisms, measured guide resistance and real mounting geometry are more useful than generic assumptions.
| Input | What to enter | Why it matters |
|---|---|---|
| Moving load | Total payload plus moving structure | Sets the gravity and inertial basis |
| Direction / angle | Horizontal, incline, vertical or hinged geometry | Changes gravity and leverage |
| Guide resistance | Measured resistance where available | Captures real friction and mechanism losses |
| Loaded speed | Required motion speed under load | Used for product matching and travel time |
| Travel / geometry | Linear travel or open/closed mount lengths | Defines preliminary stroke and installed fit |
| Actuator count | Units expected to share the work | Only a preliminary load-sharing assumption |
| Engineering margin | Project-specific multiplier | Keeps uncertainty visible instead of hidden |
Dividing force by two does not prove equal load sharing.
Uneven center of gravity, frame stiffness, mounting tolerances, racking and timing differences can place more load on one actuator. Treat the per-actuator value as a preliminary starting point only when geometry is symmetric and load sharing is credible.
The output is a requirement—not a model approval.
Before selecting or releasing a design, verify the candidate at configuration level.
| Verify next | What to check |
|---|---|
| Performance | Force at required loaded speed, stroke options, static/dynamic definitions, duty and thermal limits |
| Geometry | Retracted/extended dimensions, side load, alignment, brackets, hinges, frame strength, clearance and end stops |
| Gravity safety | Braking or holding behavior where a gravity-loaded mechanism could back-drive or fall |
| Environment | Temperature, corrosion, contamination and ingress requirements |
| Electrical system | Supply voltage/current, feedback, limits, controller and synchronization |
Carry the requirement forward without losing the assumptions.
The sizing output becomes more useful when it moves into product matching, dimensional verification and system review as one traceable requirement set.
Use the result as an engineering input.
Keep uncertainty visible and verify the real mechanism before release.
What should I measure before using the calculator?
Start with motion type, total moving load, required travel, target loaded speed and actuator count. Add travel angle and resistance for direct motion; add hinge, center-of-gravity and actuator mounting geometry for pivoting mechanisms.
Why can a hinged application need more actuator force than the load weight?
The actuator creates torque through a lever arm. When its line of action passes close to the hinge, the perpendicular moment arm becomes small and required actuator force rises.
Is actuator stroke always equal to load travel?
No. That approximation applies only to aligned direct motion. Hinges, levers, angled mounts and other linkages convert actuator travel into a different load path.
How should I choose the engineering margin?
Use a factor that reflects uncertainty in load, friction, impact, wear, geometry and operating conditions. Keep the factor visible in the record; it does not replace structural or safety analysis.
Can I divide the force equally between two actuators?
Only as a preliminary assumption when geometry is symmetric, the structure is sufficiently stiff and the actuators remain coordinated. Validate actual load sharing.
Send the requirement set when geometry or operating conditions remain uncertain.
Include the mechanism sketch, load, target speed, required travel, mounting geometry, duty, environment and calculated assumptions.
Request engineering review →