Ultra Motion’s advanced actuators deliver precision control in extreme environments. Their innovative solutions enhance reliability, efficiency and performance in autonomous applications.
Actuators are essential components in unmanned systems, converting electronic signals into precise mechanical movements. They enable critical functionality such as thrust vector control, landing gear deployment and control surface manipulation in UAVs. In unmanned surface and subsea vehicles, actuators manage rudder movements, hydrofoil adjustments and payload deployment. Their performance directly affects the accuracy, reliability and responsiveness of autonomous systems, making advanced actuator technology a key enabler for next-generation unmanned platforms.
In demanding applications, actuators must withstand extreme environments, including high-vibration aerospace conditions, deep-sea pressure and rapid temperature fluctuations. Innovations in actuator design, such as non-contact absolute position feedback and dual-redundant motor configurations, help enhance performance and reliability. Long Island, New York based Ultra Motion’s innovative actuator technology provides engineering solutions that ensure precise, fail-safe operation in autonomous applications.
Ultra Motion designs and engineers actuators for specialized applications, particularly in harsh environments like subsea, space and aerospace. They have patented Phase Index absolute position feedback technology, which has become the core of their products. All their actuators feature built-in control electronics and absolute position feedback, making them strong performers in demanding applications, including high-shock environments, submersible marine systems and aerospace.
CURRENT PRODUCT PORTFOLIO AND UNMANNED APPLICATIONS
Ultra Motion products for the unmanned vehicle space include the AM and AU Servo Cylinders. The AM (Air Model) is designed for high shock and vibration resistance, while the AU (Underwater Model) is a pressure-compensated, oil-filled actuator for submerged applications. The AM model is widely used in thrust vector control for smaller rocket engines, first-stage applications and orbital transfer vehicles. Ultra Motion Mechatronics Engineer Tom Quartararo explained, “We also see it used for control surface manipulation in fixed-wing drones, landing gear and swashplate/tail rotor control in rotorcraft. Additionally, it’s used in uncrewed surface vehicles for rudder and accessory deployment.”
The AU model, rated for depths of 6,000 meters or more, is used in ROVs for dive planes, pin release for buoys/sensors and hydrofoil control applications. “We also recently introduced the L-Series Servo Actuator, which offers zero backlash due to its ground ball screw and duplex angular contact bearing design,” Quartararo said. “Unlike typical rotary servos with 0.6–1 degree of rotational backlash, our preloaded assembly is able to provide better control authority. This is particularly valuable in high-speed, high-dynamic drone applications.”
The firm has developed a dual-redundant version of this actuator, duplicating the motor and control electronics while triplicating absolute feedback sensors. This has drawn interest for use on autonomous rotorcraft, as these aircraft experience significant oscillatory loads and zero axial backlash significantly improves reliability.
Ultra Motion’s Phase Index non-contact position sensing enhances actuator performance in unmanned systems. Quartararo explained, “In UAVs, absolute position feedback is critical. Other methods, like incremental feedback, require homing sequences, which isn’t feasible mid-flight. If there’s a power glitch, a UAV relying on incremental feedback would have to home all control surfaces to zero—obviously a major issue.”
The Phase Index technology provides: Absolute position feedback with no need for recalibration; non-contact sensing, eliminating wear-and-tear issues; minimal mass and footprint, allowing triplicated feedback without adding bulk and no battery requirement, meaning it remains reliable in extreme environments.
“It’s currently in all our actuators and has even been used in spacecraft that successfully landed on the Moon,” Quartararo explained. “Across various environments—rocket engines, rotorcraft swashplates and wave-crashing USVs—our feedback system ensures reliable and accurate control.”
DESIGNING FOR HARSH ENVIRONMENTS
Ultra Motion ensures its actuators perform reliably in extreme environments, from space to subsea, using a robust product development and testing cycle. Quartararo said, “Many of our harsh-environment actuators, like the AM, L-Series, and T-Series, stem from a 15-year collaboration with SpaceX. We developed the control actuator for the SuperDraco engines used in Crew Dragon’s launch escape system. That project taught us a lot about designing for extreme conditions.”
On the topic of customization for unique customer needs, Quartararo said:
“Our goal is to provide commercial off the shelf solutions with extensive standard options, which cover about 90% of applications. However, since we’re a small and agile company, we frequently modify mechanical designs, firmware and electrical components to meet specific customer needs.”
Examples of customization include custom mounting configurations, material substitutions for specialized applications and firmware updates to support different communication protocols. Customers receive a custom part number, and the modifications are treated as extensions of the standard product line rather than full custom builds.
ACTUATOR HEALTH MONITORING & REDUNDANCY
Ultra Motion handles actuator health monitoring and redundancy by means of built-in firmware that manages motor control, communication and telemetry. Onboard sensors monitor the actuator temperature, bus voltage and internal humidity, using a custom-molded desiccant for long-term moisture absorption.
Flight computers query actuators for telemetry, allowing users to make informed decisions. For example, monitoring running current trends can predict failures before they occur. “However,” Quartararo added, “actuators don’t automatically shut down in overheating scenarios—we let users decide, since in many UAV applications, it’s preferable for the actuator to keep working rather than causing a critical system failure.”
OPTIMIZING UAV EFFICIENCY
Actuators play a role in optimizing UAV airframe efficiency. Their high-accuracy feedback ensures precise control surface positioning, reducing instability and improving path tracking. High-efficiency ball screw design offers up to 95% efficiency, outperforming traditional gear trains and hydraulics. Moving to all-electric actuation eliminates the need for bulky hydraulic systems, improving UAV power efficiency and reliability.
In terms of the market segments stimulating growth, Quartararo said, “We’re focusing on autonomous systems rather than Advanced Air Mobility [AAM], as AAM has more regulatory hurdles. Our primary markets include defense [ISR, UAVs, UGVs, USVs]; energy sector monitoring equipment, for example for offshore wind farms, oil & gas inspections and uncrewed surface vehicles [USVs].”
“The USV sector is currently experiencing strong growth, driven by both commercial applications like energy and surveying and geopolitical factors driving defense autonomy initiatives. Many surface vehicle operators are now adopting shallow-submerged, pressure-compensated actuators, repurposed from our subsea technology.”
Quartararo explained, “Our dual-redundant L-Series actuator is a game-changer, as very few redundant linear actuators exist outside of extremely high-end markets. Also, we manufacture everything in the U.S., with direct customer support—unlike many suppliers that require navigating distributor chains. We focus on high-quality, CNC-machined components with zero compromises on reliability.”
