Electrifying Control Systems: How Electric Actuators Transform Aerospace

When we think of aerospace electrification, propulsion systems come to mind first. But a more immediate opportunity exists in an overlooked area: control systems and aerodynamic surfaces. In a new article published in Aero-Mag, Helix’s Chief Engineer of Aerospace, Derek Jordanou-Bailey, explains how electrifying hydraulic actuators can deliver substantial gains in aircraft performance, maintenance, and emissions.

Hydraulic systems have dominated aerospace control for decades, but they carry significant inefficiencies. Converting only about 50% of electrical power into useful work, hydraulic systems require high-pressure infrastructure—pipes, pumps, accumulators, and valves—that adds mass and complexity. Electric motors, by contrast, achieve conversion efficiencies of over 95%, delivering the same output force with significantly less mass and eliminating the need for complex hydraulic networks.

The benefits cascade throughout the aircraft. Lower actuator mass, simplified infrastructure, and reduced power generation requirements all decrease overall weight, lowering drag and fuel consumption. Equally important is the maintenance advantage: electric motors have only one moving part, drastically reducing the inspection, maintenance, and repair burden compared to precision-toleranced hydraulic systems. The result is improved reliability, lower operating costs, and reduced downtime—all while improving emissions performance.

Read the full article: Electrifying Control Systems  – Aerospace Manufacturing