Linear Actuator Calculator & Configurator
Free interactive tool by FIRGELLI Automations — the actuator engineering team trusted since 2002.
What This Tool Does
The FIRGELLI Actuator Configurator is a physics-based engineering calculator that helps you determine exactly which linear actuator you need for lid, hatch, door, panel, trapdoor, tonneau cover, and similar hinged applications. It replaces manual trigonometry and torque calculations with an interactive simulator that computes force requirements, stroke length, and actuator geometry in real time.
Unlike simple force calculators, this tool includes a complete actuator catalog with 30+ models, real stroke option data, closed and open dimensions from our engineering database, and a scoring algorithm that ranks every actuator by compatibility with your specific application.
Three Integrated Tools
Simulator — Physics-Based Force & Stroke Calculator
Enter your lid weight (5–500 lbs), lid length (5–80 inches), actuator mounting position along the lid, and base mount coordinates. The simulator uses torque physics computed across the full 0° to 90° opening arc to determine peak force and required stroke length. An animated canvas shows the actuator extending as the lid opens, with a live force gauge and stroke readout. Adjust the safety multiplier (0× to 3.0×) to account for friction, seal resistance, and real-world conditions. The recommended safety factor is 1.5×.
Selector — Automatic Actuator Matching
Input your force, stroke, and speed requirements (or let the Simulator calculate them for you) and the Selector instantly ranks every actuator in the FIRGELLI catalog. Each actuator card shows a percentage match score based on force capacity, available stroke options, and speed rating. Cards display the best available stroke length, closed and open physical dimensions, IP rating, and feedback sensor availability. Actuators that can't meet your requirements are clearly marked with red indicators showing why they fall short.
Compare — Side-by-Side Specification Analysis
Select up to three actuators and compare them across every specification: force range, stroke options, speed, IP rating, feedback capability, all available stroke lengths, and physical dimensions. Bar charts highlight which actuator wins in each category, and a radar plot gives you a visual overview of the competitive landscape. A verdict summary explains the engineering trade-offs between your selections.
Actuator Catalog Included in This Tool
The configurator contains specifications for the complete FIRGELLI actuator lineup:
| Actuator Model | Force Range | Stroke Range | Speed | IP Rating |
|---|---|---|---|---|
| Super Duty Actuators | 150–450 lbs | 2–40" | 0.39–0.59 in/s | IP54 |
| Classic Rod Actuators | 35–200 lbs | 1–40" | 0.59–1.54 in/s | IP54 |
| Bullet Series (36 Cal) | 35–200 lbs | 2–30" | 0.59–1.54 in/s | IP54 |
| Industrial Actuators | 400–2200 lbs | 6–30" | 0.27–0.55 in/s | IP66 |
| Optical Series (OS) | 35–400 lbs | 1–30" | 0.59–1.54 in/s | IP54 |
| Utility Actuators | 35–150 lbs | 2–30" | 0.59–1.18 in/s | IP54 |
| Micro Pen Actuators | 4–16 lbs | 1–6" | 0.30–0.40 in/s | IP54 |
| + 23 more models | Including C-Series, E-Series, Adjustable Limit Switch, Miniature Track, Heavy Duty Track, Column Lift, and specialty actuators | |||
Common Applications
This calculator is used for any application where a linear actuator must cause rotational motion about a hinge or pivot point. Common use cases include: trap doors and cellar access hatches, tonneau covers on pickup trucks, marine hatches and boat covers, industrial equipment lids and panels, cabinet doors and hidden TV lifts, greenhouse vent openers, armored vehicle windows, agricultural equipment covers, solar panel tilt mechanisms, and any lid or door that opens on a hinge from 0° to 90°.
The Physics Behind the Calculator
The calculator uses torque summation around the pivot point. At any lid angle θ, the lid's weight creates a torque equal to Weight × (Lid_Length/2) × cos(θ). The actuator must generate an equal and opposite torque through its mounting geometry. The required actuator force = (Weight × CG_Distance × cos(θ)) / (Mounting_Distance × sin(effective_angle)), where the effective angle is the angle between the actuator's line of action and the lid surface. This force varies throughout the opening arc — it's typically highest when the lid is nearly horizontal (0°) and decreases as the lid approaches vertical (90°). The calculator evaluates every degree from 0° to 90° and reports the peak force as the design requirement.
About FIRGELLI Automations
FIRGELLI Automations has been designing and manufacturing electric linear actuators since 2002. Our product range includes over 30 actuator models with forces from 4 lbs to 2,200 lbs, strokes from 1 inch to 50 inches, and both 12V and 24V DC operation. All actuators include built-in limit switches and are available with optional feedback sensors (Hall Effect, optical encoder, or potentiometer) for position control and synchronization.
Our engineering team has decades of actuator experience from automotive companies including Rolls-Royce, BMW, and Ford, particularly with the industry transition from hydraulic to electric actuation. This calculator was built by the same engineering team that helps customers size actuators every day.
Technical Support: [email protected] | 1-866-226-0465
Shop Actuators: firgelliauto.com/collections/linear-actuators