VALEMA · Project

Flight-Certified Electric Actuators Replacing Hydraulics in Regional Aircraft Controls

transportPilotedTRL 6

Imagine every time a pilot moves the wing flaps on a plane, heavy hydraulic pipes carry fluid to make it happen — like using a fire hose to water a garden. VALEMA built and certified electric motors that do the same job but are lighter, simpler, and easier to maintain. They manufactured complete actuator-and-controller sets for ailerons, spoilers, and winglet flaps, then got them approved for actual test flights on a regional aircraft demonstrator. Think of it as swapping your car's old hydraulic power steering for a modern electric one — but for airplanes, where every gram and every safety check matters enormously.

By the numbers

Electronic control units manufactured across 3 flight control surfaces (4 aileron + 6 spoiler + 10 winglet/flap/tab)

Electromechanical actuator units built for the aileron system

EMA units for the spoiler system

Backup aileron servos delivered

Consortium partners across 2 countries (Spain, Italy)

80%

Industry participation ratio in the consortium

The business problem

What needed solving

Aircraft manufacturers are under pressure to move from heavy, maintenance-intensive hydraulic flight control systems to lighter, more efficient electric alternatives. But certifying new electromechanical actuators for flight-critical applications is extremely expensive and time-consuming, requiring compliance with DO-254 and DO-178B standards. Companies need validated, certification-ready electric actuator solutions they can integrate without starting the approval process from zero.

The solution

What was built

The project manufactured and delivered complete electromechanical actuator (EMA) and electronic control unit (ECU) hardware for three aircraft control surfaces: 4 EMA units and 4 ECUs for ailerons, 6 EMA units and 6 ECUs for spoilers, 10 ECUs for winglet/flap/tab, plus 5 backup aileron servos. All units underwent certification under DO-254 (hardware) and DO-178B (software) to obtain permit to fly on the FTB2 regional aircraft demonstrator.

Audience

Who needs this

Regional aircraft manufacturers transitioning to more-electric architecturesTier-1 flight control system suppliers replacing hydraulic actuatorsElectromechanical actuator companies seeking aerospace certification expertiseAircraft MRO providers looking to simplify flight control maintenanceDefense contractors developing electric actuation for UAVs or military aircraft

Business applications

Who can put this to work

Aerospace OEMs & Tier-1 Suppliers

enterprise

Target: Aircraft manufacturers and flight control system integrators

If you are an aircraft manufacturer or Tier-1 supplier still relying on hydraulic flight control actuators — this project developed and flight-certified electromechanical actuators (EMAs) with dedicated electronic control units (ECUs) at TRL 6. They delivered 4 EMA units for ailerons and 6 for spoilers, plus 20 ECU units across three control surfaces, all certified under DO-254 and DO-178B for permit to fly. This could accelerate your transition to more-electric aircraft architectures without starting certification from scratch.

Aircraft MRO & Aftermarket Services

mid-size

Target: Maintenance, repair, and overhaul companies specializing in flight control systems

If you are an MRO provider dealing with costly hydraulic system maintenance — electromechanical actuators eliminate hydraulic fluid, hoses, and pumps from flight control surfaces. VALEMA's units were designed with optimized manufacturing routes that minimize raw material use and environmental impact. Fewer hydraulic components means fewer leak inspections, less fluid disposal, and simpler line-replaceable units for your maintenance crews.

Electric Actuator & Motor Manufacturers

any

Target: Companies producing high-reliability actuators or motors for aerospace or defense

If you are an actuator manufacturer looking to enter or expand in the aerospace flight-critical market — VALEMA demonstrated a complete certification pathway under DO-254 (hardware) and DO-178B (software) for electromechanical actuators on a regional aircraft. The project covered aileron, spoiler, and winglet/flap/tab systems with a consortium of 5 partners across Spain and Italy. Their manufacturing optimization work on routes, materials, and qualification tests could serve as a blueprint for your own product certification.

Frequently asked

Quick answers

What would it cost to license or adopt this actuator technology?

The project data does not include pricing or licensing terms. GMV Aerospace and Defence (Spain) led the consortium as coordinator. Any licensing or technology transfer would need to be negotiated directly with the consortium partners, likely involving IP developed under Clean Sky 2.

Can this scale to full aircraft production, not just demonstrators?

VALEMA validated at TRL 6 — system demonstration in a relevant environment (the FTB2 regional aircraft demonstrator). They manufactured 4 EMA units for ailerons and 6 for spoilers, plus 20 ECU units total. Moving to series production would require further qualification at TRL 7-8, but the certification groundwork under DO-254 and DO-178B is already done.

Who owns the intellectual property?

IP was developed under the Clean Sky 2 Joint Undertaking (JTI-CS2). Ownership typically follows the EU grant agreement rules, meaning each partner retains IP for their contributions. GMV Aerospace and Defence coordinated, with 4 other partners across Spain and Italy sharing development work.

What certifications and regulatory approvals does this have?

The project specifically targeted permit-to-fly certification from airworthiness authorities. Hardware was certified under DO-254 and software under DO-178B — these are the standard aerospace design assurance guidelines required by EASA and FAA. This covers the aileron and spoiler ECU designs.

How long did development and certification take?

The project ran from June 2017 to July 2022 — approximately 5 years. This covered manufacturing, assembly, qualification testing, and certification activities. The EMAs and ECUs were based on designs from a prior Clean Sky 2 call, so the total development timeline including initial design was longer.

How does this integrate with existing aircraft systems?

The EMAs and ECUs were designed for the FTB2 regional aircraft demonstrator's flight control system, covering ailerons, spoilers, and winglet/flap/tab surfaces. Integration includes backup aileron servos (5 units delivered) for redundancy. The electronic control units manage all actuator commands, making them drop-in replacements for hydraulic actuators on those surfaces.

Is technical support available for implementation?

The consortium includes 5 partners with 80% industry participation, led by GMV Aerospace and Defence. With 4 industry partners and 1 research organization across Spain and Italy, technical expertise spans manufacturing, electronics, and certification. Support availability would depend on commercial agreements with the consortium.

Consortium

Who built it

The VALEMA consortium is heavily industry-driven with 4 out of 5 partners (80%) from the private sector and only 1 research organization — a strong signal that this technology was built for real-world deployment, not academic exploration. Led by GMV Aerospace and Defence, a major Spanish defense and space company, the partnership spans Spain and Italy, two countries with significant aerospace manufacturing capability. The presence of 2 SMEs alongside larger firms suggests a supply chain approach where specialized smaller companies handle specific actuator or electronics components. For a business looking to adopt this technology, this consortium composition means the partners already understand manufacturing constraints, certification requirements, and commercial realities.

GMV AEROSPACE AND DEFENCE SACoordinator · ES
UMBRAGROUP SPAparticipant · IT
ARQUIMEA ADVANCED SYSTEMS S.A.participant · ES
FUNDACION TECNALIA RESEARCH & INNOVATIONparticipant · ES
SKYLIFE ENGINEERING SLparticipant · ES

How to reach the team

GMV Aerospace and Defence SA is headquartered in Spain. As a major defense contractor, they have public-facing business development contacts on their corporate website.

Order a report on this consortium See GMV AEROSPACE AND DEFENCE SA profile →

Next steps

Talk to the team behind this work.

SciTransfer can connect you directly with the VALEMA consortium to discuss technology licensing, manufacturing partnerships, or integration of flight-certified electromechanical actuators into your aircraft programs. Contact us for a detailed briefing.

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