Progressive Automations develops custom electric linear actuator solutions by modifying proven actuator platforms to meet specific mechanical, electrical, and environmental requirements. Depending on the platform and project, modifications may include stroke and retracted length, voltage, force and speed, feedback, connectors, mounting interfaces, and environmental protection. The process can include application review, quotation, drawing approval, prototyping or qualification, and production.
- Custom modifications based on established Progressive Automations actuator platforms
- Engineering and drawing support before production
- Paths for customized units, qualification samples, and volume orders
- Sales and application support for B2B and B2C customers
Discuss a custom actuator project
When Should You Customize an Actuator Instead of Engineering One In-House?
Customizing a proven actuator platform is often the practical alternative to designing an actuator from the ground up. It can reduce the amount of component sourcing, motor and gearbox selection, housing design, sealing work, control integration, validation, and production planning your team must own. It is a strong fit when the required motion is close to an existing platform, but the installation envelope, wiring, feedback, stroke, or mounting details are not.
A clean-sheet actuator may be appropriate when the project requires a new architecture, unusual materials, proprietary mechanisms, or performance outside the capability of an existing platform. That path normally carries a larger engineering scope, a higher minimum order, and possible development or tooling fees. A feasibility review should determine which path applies before schedule or unit pricing is committed.
What Can Be Customized on a Linear Actuator?
Actuator specifications are interdependent. A change to stroke, force, speed, gearing, screw type, or voltage can affect retracted length, current draw, duty cycle, thermal performance, service life, and cost. The final configuration should be reviewed as a complete system rather than as a list of isolated options.
| Parameter | Typical starting point | Potential modification | Required input |
|---|---|---|---|
| Stroke/length | Model-dependent | Application-specific stroke or pin-to-pin length | Travel and installation envelope |
| Force/speed | Model-dependent | Gearing, motor or screw configuration where feasible | Load, speed and duty cycle |
| Voltage | Platform-dependent | Alternative supported voltage | Power source and controls |
| Feedback | Selected Hall or potentiometer models | Supported feedback or direct signal access | Accuracy and controller type |
| Protection | Model-dependent IP rating | Sealing or material changes where feasible | Operating environment |
| Connector/cable | Standard wiring | Specified connector, cable length or in-line protection | Part number, pinout, and cable spec |
| Mounting | Standard clevis orientation | Modified interface, orientation, or bracket | Drawing and load direction |
Mechanical configuration
- Stroke and retracted length
- Force and speed targets
- Gear ratio and screw configuration
- Front and rear mounting orientation
- Housing dimensions and mounting brackets
- Manual override where supported
- Drop-in replacement dimensions
Electrical, feedback and control configuration
- Platform-supported operating voltage
- Current requirements, wire length, and connector
- Limit-switch configuration and in-line protection
- Hall-effect, potentiometer, encoder or other supported feedback
- Controller, PLC, or communication compatibility
- Synchronization and closed-loop control requirements
Environmental protection and materials
- Required ingress protection
- Operating temperature range
- Water, dust, corrosion, vibration, and shock exposure
- Housing, rod, and hardware material requirements
- Indoor, outdoor, marine, or washdown use
- Applicable documentation, test, or certification requirements
Lead Screw vs. Ball Screw for a Custom Actuator Build
The screw converts motor rotation into linear movement. A lead screw uses sliding contact between the screw and nut; a ball screw uses recirculating balls to reduce friction. Neither is universally better. The right choice depends on load, speed, duty cycle, efficiency, holding behavior, noise, accuracy, maintenance, space, and cost.
| Consideration | Lead screw | Ball screw |
|---|---|---|
| Efficiency | Lower because the nut slides on the screw | Higher because rolling balls reduce friction |
| Holding | Some designs resist back-driving; verify the actual lead and load | More likely to back-drive and may require a brake |
| Speed/duty | Often suited to moderate speed and intermittent duty | Often preferred for higher speed or duty |
| Noise/upkeep | Can be quieter; material and lubrication needs vary | Ball recirculation can add noise; lubrication is important |
| Cost/complexity | Usually simpler and more economical | Usually higher cost and more complex |
| Best fit | Moderate performance, quiet motion, compact or cost-sensitive builds | Efficiency, precision, repeatability or higher-duty motion |
Many compact rod-style actuators are built around a proven screw-and-gear platform. If a project specifically requires a ball screw, a lead screw, low backlash, or resistance to back-driving, state that requirement in the RFQ. Availability must be confirmed for the selected Progressive Automations platform.
How Does a Custom Actuator Project Move from Requirements to Production?
- Define the application. Document dynamic and static load, push or pull direction, stroke, speed, voltage, duty cycle, available space, mounting geometry, feedback, environment, quantity, and target date.
- Select the closest platform. Starting with a proven actuator can reduce engineering time, tooling exposure, and technical risk.
- Complete an engineering review. Confirm force margin, speed under load, current draw, mounting alignment, control method, feedback, and environmental protection.
- Review quotation and commercial terms. Align on unit pricing, development or tooling charges, minimum order, qualification units, testing, shipping, and schedule.
- Approve drawings and specifications. Use the approved dimensional drawing, electrical interface, performance requirements, and revision as the controlled definition.
- Build and validate the qualification unit. Check form, fit, function, load, speed, current, controls, and environmental requirements in the real assembly.
- Move into production. Approve the sample or pilot result, schedule production, define inspection requirements, and retain change control for future orders.
Who Offers Rapid Prototyping for Custom Actuators?
Progressive Automations supports engineering-led custom actuator development and can evaluate a qualification or prototype path for an eligible project. Our Made-in-Canada electric linear actuators and control systems also enable faster prototyping and custom solutions through local engineering. The right path depends on whether the requirement is an in-capability modification or a clean-sheet design, so the quotation should confirm prototype quantity, deliverables, and timing.
A prototype is most useful when it answers defined questions: Will the actuator fit the envelope? Does the linkage achieve the required travel? Can the control system read the feedback correctly? What are speed and current under real load? Does the assembly tolerate the intended environment? A sample without a written validation plan can create false confidence.
What Are the Lead Times, Minimum Orders, and Pricing Tiers?
We offer three main order paths; however, these can be treated as program guidance; the written quotation should control the actual scope, timing, and commercial terms for a project.
| Order path | Development time | Minimum order | Development fee | Scope |
|---|---|---|---|---|
| Standard unit | In stock / zero development time | None | No charge | Existing configuration |
| Customized unit | Up to 8 weeks | None | No charge; air freight may apply | Within unit capability |
| Clean-sheet design | Specification-dependent | 1,000+ units | Development and mold fees may apply | Designed to specification |
Fast turnaround depends on a complete application brief, a close platform match, available components, prompt drawing approval, and a focused validation plan. Combined modifications, custom components, tooling, certification work, environmental testing, large quantities, or production capacity constraints can extend the schedule.
How volume affects pricing
We offer flexible and dynamic pricing for OEM customers. Pricing is generally shaped by initial quantity, expected annual volume, custom parts, setup or tooling, testing, packaging, inventory strategy, and shipping. Ask for prototype, first-production, and forecast-volume pricing in the same RFQ so the commercial path is visible.
How Do You Get CAD Support and Drawings for a Custom Actuator?
Begin with the installation envelope and interface requirements, then provide a drawing or model of the surrounding assembly when possible. We offer technical resources, including datasheets, wiring diagrams, and 3D models for many standard products. For a custom project, request the specific mechanical and electrical deliverables needed for review; file formats and availability should be confirmed for the selected platform.
- 2D dimensional drawing with stroke, retracted length, and mounting dimensions
- 3D CAD or STEP model when available and agreed
- Connector type, pinout, voltage, current, and feedback signals
- Load direction, mounting geometry, and alignment notes
- Controller or PLC interface requirements
- Approved specification number and revision
Use the approved drawing revision to govern the qualification unit, production order, and future replacement orders. Revision control prevents a connector, cable, bracket, or internal option from changing without review.
Review actuator technical resources
How Are Custom Actuators Tested Before Production?
Testing should be matched to application risk. At Progressive Automations, our OEM process includes testing and validation capabilities, and operates an ISO 9001:2015 certified quality management system. It is important to not assume every project receives every possible test; define the required test method, sample size, acceptance criteria, and report deliverables in the quotation.
- Performance: dynamic and static load, speed under load, current draw, stroke repeatability, duty cycle, and feedback accuracy
- Mechanical and environmental: mounting alignment, ingress protection, temperature, vibration, shock, corrosion resistance, and life cycle where applicable
- Production quality: approved-sample comparison, incoming component checks, functional testing, inspection records, and non-conformance handling
What Support Is Available in the United States and Canada?
Progressive Automations serves US and Canadian customers through North American sales, product recommendations, warehousing, and engineering customer support. Our Made-in-Canada actuators and control solutions are designed, assembled, and tested in Metro Vancouver using carefully selected international components.
For buyers comparing US suppliers for custom-stroke linear actuators, evaluate more than the office address. Ask where engineering review occurs, where the qualification unit and production units are built, who controls the drawing revision, what tests are performed, how replacement configurations are identified, and what support is available after launch.
Custom Actuator Project Examples
High-frequency position feedback for a medical application
A customer using the PA-12 needed position data at a 500 Hz refresh rate. Instead of requiring the actuator’s internal controller to service and transmit every position request, Progressive Automations added a direct potentiometer-feedback connection to the customer’s control system. The customer could process the analog position signal directly while keeping the compact actuator platform.
Drop-in replacement with custom mounting and wiring
A customer needed a PA-09 configuration that would fit an existing assembly without redesigning the surrounding mechanism. Progressive Automations custom manufacturing included rotated front and rear mounting interfaces, a customized actuator length, an in-line fuse on the motor wire, and a DT04-2P connector. The modifications aligned the actuator with the customer’s mechanical and electrical interfaces.
What Warranty and Long-Term Support Apply?
We offer a warranty of 18 months for linear actuators against defects in materials and workmanship and optional extended plans. Custom project coverage should be confirmed in the quotation or supply agreement, especially when the actuator includes nonstandard parts, customer-specified components, or application-specific testing.
- Reference future orders by the approved drawing or configuration number
- Plan spare units for production-critical equipment
- Keep the electrical interface and controller revision with the actuator record
- Define support for discontinued or revised components
- Retain qualification and inspection records appropriate to the project
How Do You Prepare an Effective Custom Actuator RFQ?
A complete RFQ helps engineering determine whether a standard unit, a modified platform, or a clean-sheet design is appropriate. Include target values and acceptable ranges; a range can give the team more options than a single hard number.
- Mechanical: dynamic and static load; push or pull; stroke; retracted length; speed; mounting geometry; available space
- Electrical and control: voltage; current limit; control method; feedback; connector; cable; PLC or controller details
- Environment: duty cycle; indoor or outdoor use; water and dust; temperature; vibration; corrosion; required standards
- Commercial: qualification quantity; initial order; annual volume; target price; delivery date; packaging; documentation and testing
Attach sketches, CAD files, photos of the installation, existing actuator part numbers, and test requirements. State which requirements are mandatory and which can be traded against cost, speed, or package size.
Request a custom actuator quote
Frequently Asked Questions
Is there a minimum order quantity for a custom actuator?
There is no minimum order quantity requirement for customized units that stay within an existing unit’s capability. For clean-sheet designs, a quantity of 1,000+ units will generally be required. The quotation should confirm which category applies and whether custom components introduce supplier minimums.
How long does a custom actuator project take?
Customized units generally take up to eight weeks, and clean-sheet designs are specification-dependent. Engineering review, drawing approval, parts, testing, quantity, and production capacity can change the schedule.
Are there engineering or tooling fees?
We do not charge development fees for customized units within unit capability, although air-freight fees may apply. Development and mold fees will generally apply to clean-sheet designs.
Can Progressive Automations provide CAD files and dimensional drawings?
Yes, Progressive Automations publishes datasheets, wiring resources, and 3D models for standard products. Custom-project drawing and CAD deliverables depend on the platform and project agreement. Specify the file format and approval document you require in your RFQ.
Can I test a prototype before a production order?
Reach out to our team and ask for a qualification or prototype path during engineering review. Availability, quantity, timing, and cost depend on the modification scope. Define the form, fit, function, and environmental checks that must pass before production approval.
What warranty applies to a custom actuator?
We offer a warranty of 18 months for linear actuators against defects in materials and workmanship and optional extended plans. Custom project coverage should be confirmed in the quotation or supply agreement, especially when the actuator includes nonstandard parts, customer-specified components, or application-specific testing.
Where are custom actuators designed?
Qualifying custom actuators are designed and tested in Canada to ensure they meet our quality and performance standards.
Who offers fast prototyping and CAD support for custom actuators?
Progressive Automations can evaluate custom configurations, qualification units, and drawing support through our custom-order program. Start with a complete application brief and ask our sales and support team to confirm the prototype path, CAD deliverables, and schedule for the selected platform.
What information is required for a quotation?
Provide load, stroke, speed, voltage, duty cycle, retracted length, mounting geometry, control method, feedback, connector, environment, required testing, qualification quantity, annual volume, and target date. Attach drawings or photos when available.
Build the Actuator Around Your Application
Share the mechanical, electrical, control, environmental, and commercial requirements with our support team. Our product specialists can evaluate the closest actuator platform and determine the appropriate customization, qualification, and production path.