Advanced motion control technologies are essential to modern aerospace design, supporting a wide range of safety-critical and comfort-driven applications. In aerospace, motion control components—such as gas springs, actuators, and dampers—are integral to nearly every commercial aircraft, rocket, satellite, and space vehicle. These critical elements support flight safety and transport functions, from the dependable deployment of landing gear and cargo doors to the smooth, ergonomic operation of seating for pilots and passengers.
However, for aerospace manufacturers achieving the rigorous safety, reliability, and performance standards often requires more than standard off-the-shelf components—it demands specialized motion control solutions designed to deliver reliable performance under unique specifications and extreme conditions. “In many cases, the components must be fully or partially customized to meet specific application requirements. Even when development begins with a standard part, various modifications are frequently necessary such as changes in stroke length, force calibration, material composition, damping characteristics, and mounting hardware,” says Brian Ingoldsby, engineering manager at Bansbach Easylift of North America Inc., a global supplier of motion control devices, systems, and components since 1919.
According to Ingoldsby, the process of modification or customization begins with evaluating the specific functional requirements, such as whether the component must counterbalance a load, provide damping, or perform consistently under defined temperature, pressure, or altitude conditions. Material selection is particularly important, as components must often meet weight, corrosion resistance, and fatigue criteria unique to aerospace environments.
“In aerospace engineering projects, key design considerations typically include space constraints, force output, mounting geometry, material selection, and environmental exposure. These factors are assessed in close collaboration with the customer, often resulting in a fully customized product tailored to the exact specifications of the application,” says Ingoldsby.
The specialized motion control components also must meet all necessary testing and classification requirements to comply with FAA and EASA regulatory standards. Each part must meet the RTCA DO-160 testing standards, an international benchmark designed to ensure airborne equipment can withstand the harsh conditions encountered in aviation. This necessitates a deep understanding of certification protocols and the ability to manage the complete approval process.
For these reasons, a growing number of aerospace equipment designers are choosing to collaborate closely with motion control engineers from the earliest stages of a project. To facilitate such cooperation, leading companies like Bansbach assign dedicated engineers to provide input, explore design options, offer technical recommendations, and develop solutions that enhance overall system performance.
“The ultimate objective is to streamline the OEM’s design process, reduce their development time, and ensure that the final product meets the performance specifications,” says Ingoldsby.
Manual Motion Control
In aerospace systems, gas springs play a vital role in enabling safe, controlled, and ergonomic motion. From landing gear doors to access panels and cargo hatches that must remain safely open during maintenance or loading, gas springs provide the necessary force control and damping. Within the cabin, locking gas springs combine controlled motion with the ability to lock in a fixed position, a key feature in adjustable seating, stowable tray tables, and other reclining mechanisms.
Gas springs are also found on nearly every rocket, satellite, or space vehicle, as well as in equipment used for ground support and launch operations. One example is for separation events on rockets, where components are ejected during different flight stages.
Dampers are widely used in aerospace applications to control motion, manage energy, and reduce vibration in various systems throughout an aircraft. Inside the cabin, dampers are used in seating mechanisms and overhead storage compartments to provide controlled motion. Dampers also play an important role in managing the operation of cargo doors, service panels, and passenger doors. Directional locking dampers allow manual force to override the position of the locking gas spring. This function supports both emergency use and maintenance operations.
Although gas springs and dampers share similar external appearances and basic operating principles across manufacturers, certain models are engineered with specialized design features that provide distinct advantages for aerospace applications.
Unlike some standard offerings that require OEMs to design around preset dimensions, Bansbach provides components that can be manufactured to match customer specifications. In this regard, Bansbach manufactures gas springs with rod diameters from 3 millimeters (0.12 inches) to 70 millimeters (2.75 inches), capable of lifting multiple tons.
Bansbach also incorporates innovative design elements into its products. These enhancements go beyond standard configurations and involve selection of materials, surface treatments, and internal components.
As with many aerospace components, aluminum is often selected due to its significant weight savings over steel.
Beyond material selection, advanced engineering features play a critical role in maximizing performance and extending product lifespan. For example, an integrated grease chamber can increase durability and support higher cycle counts than standard models. To further enhance longevity, the company applies a proprietary oven-cured surface treatment that improves corrosion resistance and creates a smooth, durable rod finish without compromising seal performance. As a result, treated gas springs typically last three to five times longer than conventional gas springs.
Along with mechanical durability, thermal performance is critical. Aerospace components must operate reliably across extreme temperature ranges. Consequently, additional considerations for aerospace applications include specialty seals and oils formulated for extreme environments. Components may need to withstand temperatures up to 200°C near engines, while others must perform reliably in subzero conditions. To ensure consistent performance across this wide temperature range, the company employs advanced seals engineered for both high- and low-temperature operation.
Automated Motion Control
Motion control components such as electric linear actuators provide precise, compact movement. Adoption within the aerospace sector remains limited. However, interest in the technology is steadily increasing and electric actuators hold significant promise for future aerospace applications.
Bansbach’s EasyE electric linear actuators are available in a range of lifting capacities, with customizable stroke lengths up to 1,500 mm and dynamic load capabilities up to 10,000 N. The linear design allows for a compact installation footprint, while available accessories—including controllers and handsets—simplify system integration. Turnkey actuator kits further streamline deployment by eliminating the need for separate component sourcing, programming, or integration.
The Value in High Quality Components
Using higher-quality, custom-engineered motion control components provides significant advantages for aerospace manufacturers. Whether through advanced gas springs, precision dampers, or electric linear actuators, the right components ensure that equipment will operate smoothly and reliably for the expected lifespan, while meeting the rigorous standards of modern aerospace.
By working closely with motion control experts, aerospace designers ensure components meet the highest safety standards, streamline certification, and reduce development risks.
