Complete Solutions from MACCON for the Defense Industry

MACCON has been a powerful and reliable engineering partner and system supplier for the defense industry for decades.

Military optic sensors on an army vehicle.

Defence & Security

MACCON has been an engineering partner and system supplier for the defense industry for decades. We combine high-performance electric motors, sensors, drives and controllers into customized motion solutions – from individual components to fully integrated and qualification-ready subsystems.

Our goal is to provide precise, reliable and long-term available motion-control solutions for demanding applications and harsh operating environments. Since 1982, MACCON has been a proven partner for motion-control technology in safety-critical programs and supports a wide range of defense-related applications on land, at sea, in the air and in space.

Below, we present our experience and expertise in the various defence sectors, followed by the key technologies and solutions we offer.

Application Examples

For more than 40 years, we have supported numerous defense technology applications, including:

  • Radar and antennas
  • Sensor platforms
  • Gun mounts and
  • weapon systems
  • Main battle tanks and infantry fighting vehicles
  • Drones
  • Missiles
  • Air defence
  • Pilot training centrifuges
  • Unmanned systems and robotics
  • Submarine winches and periscopes
  • Baggage and container inspection
Military optic sensors on an army vehicle.

Core Capabilities

  • Standard & build-to-spec solutions
  • Germany-based engineering, manufacturing & testing
  • Rugged for harsh environments (EMI, shock/vibration, temperature)
  • Lifecycle & compliance support (obsolescence, single-source, regulatory)

Your Partner for “Motion Under Control” in the Defence Industry

When precision, ruggedness and operational readiness are critical, MACCON is the right partner for the defense industry. With a comprehensive portfolio of high-performance motion-control components and systems – from COTS products to fully customized build-to-spec solutions – we support defense applications on land, at sea, in the air and in space.

Our portfolio ranges from motors and actuators to sensors, drives and ruggedized control solutions. With expertise across the entire lifecycle – from development and manufacturing to testing – we create solutions that can be integrated quickly and perform reliably even under the harshest conditions.

MACCON stands for advanced motion control in defense applications – powerful, adaptable and mission-ready when it matters most.

Our Ruggedized Products for Harsh Environment

Motors

High-performance motor solutions optimized for power density, precision, and mission reliability.

  • Custom motor design, manufacturing & testing in Germany
  • Torque & servo motors: Ø 35–1500mm | 0.2–20,000 Nm (nom.) | up to 20,000 rpm | 24–800V windings
  • Configuration flexibility: high-torque designs with precision sinusoidal control; zero-cogging options and slotless/ironless stators (config.-dependent)
  • Integration flexibility: frameless kits or complete assemblies (shaft/bearings); axial or radial flux; scalable modular platforms (~30 mm to >1 m)
  • Environmental hardening (as required): encapsulated windings, fail-safe magnet retention/wrap, redundancy concepts, radiation-tolerant variants, extreme-temperature capability (-250°C to +300° C)
  • Stepper capability (standard to ruggedized variants):holding torque 0.45–17 Nm | 200 steps/rev (1.8°) | NEMA-compatible

Differantiators

  • HRE-free magnet design option (no license required; config.-dependent)
  • Optional China-free supply chain
  • Zero-cogging / smooth-motion options for precision pointing and stable control loops

Controllers

  • Off-the-shelf servo drives
  • MACCON SWM Drive (12 – 650 VDC, up to 200 A) — compact, high-performance, linear amplifier versions available
  • Custom electronics design, manufacturing & testing in Germany

Actuators

  • Off-the-shelf linear and voice-coil actuators
  • Custom actuator design (industrial-grade to fully space-qualified)
  • Custom manufacturing optimized for demanding environmental and operational conditions

Sensors

  • Off-the-shelf sensors, including resolvers, encoders, and magneto-resistive sensors – radiation-hardened versions available
  • Custom resolver designs, manufacturing & testing in Germany

Engineering & Design Services

  • Electromagnetic design studies
  • Magnetic stray-field analysis
  • Servo system analysis and simulation
  • Design analyses, including:
    • Interface design
    • Mechanical design
    • Thermal analysis
    • Radiation analysis
Military optic sensors on an army vehicle.

Testing & Qualification

  • Motor performance testing
    • Resistance, inductance, cogging torque, back EMF
    • Power analysis: 10 W–300 kW
    • Torque range: 0.01 Nm–20,000 Nm
  • Sensor accuracy & resolution testing
  • Insulation testing (motors, sensors, actuators)
  • Thermal cycling & thermal-vacuum (TVAC) testing
  • Vibration testing (Sine, Random, Shock)
  • Outgassing, lubricant compatibility & corrosion testing (supported by partners) 

Custom test setups for customer-specific parameters and extended test ranges are available on request.

Technology Blocks

To meet the diverse requirements of aerospace applications, MACCON offers a comprehensive range of motion-control technologies.

We cover all essential building blocks of advanced servo systems – from motors and sensors to drive electronics and complete actuator units. Thanks to our in-house development and design expertise, combined with cooperation with selected partners, we are able to design, adapt and integrate the right solution for each project.

Below you will find our core technological competencies in the aerospace sector.

1

One of our core competencies is the development and manufacture of high-performance electric motors. We realize custom electric motors in various form factors and sizes, optimally adapted to the specific requirements of aerospace applications.

Our offering includes:

  • Torque motors in various sizes
  • Linear motors in different lengths for direct linear motion
  • Curved motors in 2D and 3D designs for curved or rotating linear motion
  • Voice coil motors for short strokes with high force
  • Stepper motors, including hybrid and permanent magnet stepper motors

 

In addition to standard designs, MACCON also manufactures special space-qualified motors optimized for operation in vacuum and radiation environments. These include zero-cogging motors for exceptionally smooth motion, quadriplex motors for redundant drive systems and advanced switched reluctance motors for high reliability.

Such custom motors are used, for example, in reaction wheels, gimbal drives and other critical space mechanisms.

 

2

MACCON offers a broad range of feedback sensors that can be combined with our motors and servo systems. Precise and robust sensor technology is essential for reliable motion control, especially in aerospace.

Our sensor portfolio for servo applications includes:

  • Tachometers for speed feedback and speed control
  • Resolvers and rugged transducers for absolute position detection, even under harsh conditions
  • Optical encoders for high-resolution digital angular feedback
  • Magnetic encoders as contactless sensors for demanding environments
  • Capacitive encoders for precise position measurement without magnetic signature
  • Absolute linear and rotary encoders for direct position measurement across the full travel or rotation range

 

These sensors are selected or designed to withstand vibration, extreme temperatures and other environmental conditions typically encountered in aerospace applications.

3

Many aerospace applications require electromechanical actuators to convert electrical energy into controlled mechanical motion – for example, to move control surfaces or deploy mechanisms.

Linear and rotary motions that were previously often implemented using hydraulic or pneumatic systems are increasingly being replaced by electromechanical actuators. Compared with conventional hydraulic or pneumatic systems, they offer several key advantages:

  • Higher dynamic performance: more dynamic and responsive motion control
  • Better controllability: precise control of position, speed and force via electronics
  • Energy efficiency: power consumption only when needed, without idle losses
  • Clean and leak-free operation: no hydraulic fluids, no oil leaks and no fluid maintenance
  • Compact performance: high force and torque output in smaller and lighter designs

Our actuators can deliver forces of up to 200,000 N and torques of up to 6,000 Nm.

MACCON develops complete servo actuator assemblies that make use of these advantages – for example, for aircraft landing gear, control surfaces or demanding space mechanisms. We integrate motors, sensors and control electronics into a coordinated overall solution.

Our designs often include redundant motors or dual-drive architectures in order to meet the high safety requirements of aerospace applications.

4

MACCON develops and supplies advanced drive electronics and controllers for aerospace applications. Our electronic controllers and drives are used, among other things, in space satellites and large ground-based telescopes, where maximum reliability and precise control are essential.

This custom electronics handles tasks such as motor commutation, feedback signal processing and communication with control computers in spacecraft, aircraft or ground-based systems. All designs undergo comprehensive environmental testing – including vibration, temperature and vacuum tests – to ensure that they meet the high requirements of aerospace applications.

Beyond individual components, MACCON is capable of supplying turnkey motion-control systems. We take responsibility for complete projects, including:

  • System design and simulation – preliminary engineering to meet the respective application requirements
  • Hardware and software development – development of custom electronics and embedded software
  • System integration and testing – assembly of components into a qualified subsystem and verification of performance

 

By supporting the entire development cycle, we ensure that all components of the motion solution work together seamlessly and meet the required quality and performance targets. The MACCON team has decades of experience in delivering integrated systems – from initial concept through to qualification.

Contact

Do you have any questions or would you like some advice?

Please feel free to send us your technical requirements or questions in writing using the contact form linked below. We will get back to you as soon as possible after receiving your enquiry.

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