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Linear Actuator Calculator Suite — Free Engineering Tools for Force, Stroke & Motion Design
Sizing an actuator correctly is one of the most common engineering challenges in linear motion design. Whether you are working with electric, hydraulic, or pneumatic actuators, the underlying physics is the same — force, torque, geometry, and friction all interact to determine what actuator your application actually requires.
Most engineers and designers discover that the force rating printed on an actuator datasheet rarely tells the full story. A 100 lb-rated actuator cannot necessarily lift a 100 lb hatch, because the mounting angle, bracket geometry, and lever arm all multiply the required force. A scissor lift amplifies force through its pantograph linkage, while a panel mounted on a wall bracket creates torque demands that depend entirely on the bracket length and attachment angle. These are not intuitive calculations, and getting them wrong means an undersized actuator that stalls or an oversized one that wastes budget and space.
FIRGELLI's calculator suite solves this by giving you interactive physics simulators for every common actuator application. Each calculator uses real engineering equations — not simplified lookup tables — and provides real-time visual feedback so you can see exactly how changing a dimension, angle, or load affects the force your actuator must deliver. Every calculator also includes a built-in actuator selector that matches your calculated requirements against our full product catalog, scoring each actuator on force capacity and stroke fit so you can move from calculation to purchase in a single workflow.
These tools are used daily by mechanical engineers, industrial designers, automation integrators, robotics teams, and DIY builders working across industries including marine, automotive, agricultural, medical, furniture, home automation, solar tracking, and stage equipment. The calculators apply equally to electric linear actuators, hydraulic cylinders, pneumatic rams, and any other device that produces linear force — the physics does not change with the actuation method.
- Lid & Hatch Calculator — Calculates actuator force for hinged lids, trap doors, tonneau covers, cellar hatches, and marine hatches using torque equilibrium around the hinge point
- Panel Flip Calculator — Solves the linkage bracket problem for wall-mounted panels, drop-down TV lifts, solar trackers, and fold-out ramps where a short bracket arm creates force multiplication
- Scissor Lift Calculator — Models multi-stage pantograph mechanisms for lift tables, vehicle platforms, stage risers, and adjustable workstations with 1–10 scissor stages
- Linear Motion Calculator — Computes push/pull force on flat or inclined surfaces including friction, gravity components, and spring return loads for sliding doors, drawers, conveyors, and gate openers
- Simple Lever Calculators — First, second, and third class lever tools for quick moment-balance calculations on basic pivot mechanisms
- Built-in Actuator Matching — Every advanced calculator scores and ranks actuators from our catalog by force capacity and stroke length, eliminating manual cross-referencing
Choosing the Right Linear Actuator Calculator
Robbie Dickson engineering note: Start with the calculator that best matches the geometry of the moving part, not just the actuator type. The same electric linear actuator can behave very differently in a hatch, scissor lift, lever, drawer slide, or lifting column because force changes with mounting angle, pivot distance, load position, friction, and stroke.
The FIRGELLI calculator suite is organized around real actuator applications so engineers, fabricators, and DIY builders can move from a sketch to a safe sizing range before selecting a product. Use the tools below to compare force, stroke, speed, duty cycle, mounting clearance, and mechanical advantage before ordering hardware.
| Application | Best calculator to start with | Main sizing risk |
|---|---|---|
| Hatches, lids, trap doors, tonneau covers | Linear Actuator Force Calculator | Pivot distance and actuator angle can multiply the required force. |
| Vertical platforms, lift tables, pantograph mechanisms | Scissor Lift Calculator | Force is highest near the collapsed position and changes through travel. |
| Simple arms, handles, and rotating levers | First, second, or third class lever calculator | Load position and fulcrum spacing control mechanical advantage. |
| Product selection after geometry is known | Actuator Configurator | Force, stroke, voltage, feedback, speed, and mounting style must all match. |
Calculator Suite FAQ
Which FIRGELLI calculator should I use first?
Use the calculator that matches the motion geometry. A lid or hatch should start with the linear actuator force calculator, a platform should start with the scissor lift calculator, and a pivoting arm should start with the correct lever calculator.
Do these tools apply to hydraulic or pneumatic cylinders?
Yes. The force, torque, stroke, and lever equations are the same for electric actuators, hydraulic cylinders, pneumatic cylinders, and other linear force devices. Product selection should still account for speed, control, duty cycle, environment, and mounting hardware.
Why does actuator force change when the mounting points move?
Moving either mounting point changes the lever arm and the angle at which the actuator applies force. A small geometry change can turn an easy lift into a high-force application, especially near the start of travel.
Core FIRGELLI Sizing Tools
How the Calculators Work — Engineering Principles Behind Every Tool
Every calculator in this suite is built on classical mechanics — the same equations taught in university engineering courses and used in professional mechanical design. The lid and hatch calculator applies moment equilibrium around the hinge axis, resolving the actuator force vector into its perpendicular component and accounting for how that component changes continuously as the lid sweeps through its opening arc. This is why the required actuator force is always higher than the static weight of the lid, and why it varies with opening angle.
The panel flip calculator extends this analysis to bracket-mounted linkages, where the actuator connects to a short lever arm rather than directly to the moving panel. The mechanical disadvantage created by a short bracket means the actuator must produce significantly more force than a simple weight calculation would suggest. The calculator solves for the exact force at every angle using the bracket length, panel center of gravity, and the changing sine of the actuator-to-bracket angle.
The scissor lift calculator uses the geometric relationship between the horizontal actuator force and the vertical lift force in a pantograph mechanism. As the scissor angle decreases toward horizontal, the mechanical advantage drops and the required actuator force increases toward infinity — which is why scissor lifts require careful geometry planning. The calculator handles multiple stages and shows you exactly where your design sits on the force curve.
The linear motion calculator resolves forces along and perpendicular to the direction of travel, incorporating both the gravitational component on inclined surfaces and kinetic friction forces based on real material coefficients. It handles flat, inclined, and vertical orientations and optionally includes spring return forces.
All calculators display results through animated diagrams and a force gauge that updates in real time as you adjust parameters, giving you immediate visual confirmation that your design is within safe operating limits. A built-in safety factor slider lets you add engineering margin from 1.0x to 3.0x, following standard practice for actuator sizing where manufacturers recommend never running actuators continuously at more than 80% of their rated force.
