Aviation lighting systems
Compact gear motor for aircraft actuation systems: less weight and size
In the aerospace industry, every gram matters.
Reducing component weight has a direct impact on aircraft efficiency, helping to lower fuel consumption and improve overall operational performance.
Within this context, we were involved in the co-design of a compact gear motor for an aircraft actuation system used to position external aircraft lighting.
The primary objective was not to minimise component cost, but to reduce weight and installation space while maintaining the torque, precision, and reliability required by aerospace standards.
The Engineering Challenge
The original system required a motor-gearbox assembly capable of:
- Delivering smooth, quiet motion
- Operating safely and reliably over extended service life
- Meeting extremely tight space constraints
- Minimising the overall weight of the subsystem
In aerospace applications, motor selection cannot be based solely on nominal torque and speed.
The torque-to-volume ratio, thermal management, vibration resistance, and mechanical integration with the gearbox are equally critical factors.
Co-Design of the Gear Motor
The project was developed through a collaborative engineering process in which our technical department worked closely with the customer's design team to define the optimal system architecture.
Motor selection was based on:
- Available installation space
- Required torque and speed performance
- Operating conditions, including vibration, temperature, and duty cycle
- The reliability and service-life requirements typical of aerospace applications
At the same time, the compact precision gearbox was engineered to achieve maximum integration with high-performance DC motors, both brushed and brushless, using optimised diameters for aerospace applications.
The Technical Solution
The resulting gear motor features:
- Compact architecture for installation in confined spaces
- High torque-to-volume ratio
- Lightweight construction through carefully selected materials
- Precision transmission for smooth, quiet operation
- Compatibility with high-performance DC motors
The final configuration achieved the required performance within a smaller installation envelope while delivering a significant reduction in the overall weight of the actuation system.
Results
The customer obtained a gear motor for an aerospace application capable of:
- Reducing the weight of the subsystem
- Maintaining the required torque and operating speed
- Ensuring continuous, reliable operation
- Meeting the stringent reliability requirements of the aerospace industry
An engineering upgrade that contributed directly to improving the aircraft's overall efficiency.
Compact Gearboxes and Gear Motors for Aerospace
This case study demonstrates how the design of precision gearboxes and gear motors for aerospace applications can transform critical constraints—such as weight and installation space—into measurable engineering advantages.
Our contribution goes beyond manufacturing. We work alongside our customers to co-design customised transmission solutions where mechanical engineering, system integration, and performance are carefully balanced to achieve the best possible result.