When it comes to automation projects, selecting the right actuator is one of the most important decisions you’ll make. Whether you’re designing an industrial machine, upgrading home automation, or creating a custom project, choosing the wrong actuator can lead to costly mistakes — from poor performance to premature failure.
At Progressive Automations, we’ve seen it all. From customers who needed a quick replacement for a 12V linear actuator to large-scale OEMs sourcing industrial actuators, one truth always remains: success depends on picking the right actuator for the job.
Here’s a detailed guide to help you avoid the most common pitfalls and choose confidently.
Every application has its own unique demands, so it’s important to define your requirements before browsing models. Key factors include:
- Load Capacity (Force): How heavy is the object you’re moving? For instance, a TV lift mechanism requires less force than an industrial lifting table.
- Stroke Length: How far does the actuator need to travel? Too short, and it won’t complete its task; too long, and you’ll waste space and energy.
- Speed: Do you need fast actuation for efficiency or slower, precise movements? A mini linear actuator may be better for smaller, delicate projects, while a high-force electric actuator is more suitable for heavy loads.
- Duty Cycle: How often will it operate within a given period? Continuous-use applications require actuators designed for longer duty cycles to prevent overheating.
Defining these requirements upfront can prevent costly trial-and-error.
Balance Force and Speed
One of the most frequent mistakes is misjudging the balance between force and speed. Linear actuators are designed with trade-offs — higher force typically means slower speeds, while faster actuators often provide less pushing power.
For example, a compact 12V linear actuator might be perfect for a lightweight, high-speed application, but it would struggle with lifting a heavy industrial panel. Conversely, oversizing with a heavy-duty actuator when you only need a light push will cost more and waste energy.
This article explains how to calculate force needs with simple formulas so you can select the right balance, check it out.
Not all actuators are built for the same conditions. The wrong choice can quickly wear down, fail, or even damage surrounding components. Consider:
- Indoor vs. Outdoor Use: Will it be exposed to rain, snow, or dust?
- IP Rating: An IP66 actuator is designed to handle water and dust, making it ideal for outdoor or industrial environments.
- Temperature Extremes: Some actuators include weather-resistant materials for hot or freezing climates.
For example, a home project like an automated trapdoor in a clean basement can use a standard actuator, while a farming machine requires an IP-rated industrial actuator for long-term durability. Explore our IP66-rated actuators for demanding environments.
Choose the Right Power and Control System![]()
Power supply and control options are just as important as the actuator itself. Most projects use a 12V linear actuator, but larger or industrial applications may require 24V or 110V.
Control is another factor:
- Wired Switches: Simple, reliable, and cost-effective.
- Wireless Remotes: Convenient for home automation and projects requiring flexibility.
- Multiple Actuator Control Boxes: Ideal when synchronizing two or more actuators.
- Smart System Integration: Some actuators can connect to home automation systems for advanced scheduling and remote access.
Check out our range of control systems to find options compatible with your chosen actuator.
Even if you’ve selected the perfect actuator, overlooking installation requirements can derail your project. Make sure you review:
- Mounting brackets and orientation
- Available space for retraction and extension
- Wiring access and cable lengths
- Compatibility with existing hardware
Consider Long-Term Performance
Thinking ahead is just as important as initial setup. Ask yourself:
- Will your actuator need regular maintenance?
- Can it withstand your application’s duty cycle for years?
- Is replacement cost and downtime acceptable if you choose a cheaper option?
Investing in a high-quality actuator upfront reduces failures and provides peace of mind. Industrial actuators, for example, are engineered for longevity and heavy-duty use, while smaller, lower-cost models are better suited for occasional, light applications.
Get Expert Guidance
Finally, remember you don’t have to make this decision alone. The team at Progressive Automations has over a decade of experience helping both DIYers and professionals find the right actuator. From mini linear actuators for robotics projects to custom OEM solutions, we’ll work with you to ensure your actuator matches your exact needs.
Final Thoughts
Choosing the right actuator may seem overwhelming at first, but it doesn’t have to be. By carefully considering force, speed, stroke length, environment, power supply, and installation needs, you can avoid the common mistakes that lead to inefficiency, breakdowns, and extra costs.
Take the time to plan, do the calculations, and use our actuator comparison tool to find the most suitable product. With the right actuator, your automation project will perform reliably and efficiently for years to come.