Ball Screws Powering the Next Generation of Braking

How Electro-Mechanical Brake Actuators Are Transforming Motion Control

As CEO of Helix Linear Technologies, I’ve had the privilege of watching our team engineer and deliver motion control solutions for some of the most demanding applications in the world. One of the most exciting shifts we’re seeing in mobility, automation, and aerospace today is the rise of the electro-mechanical brake actuator (EMBA)—a technology that is rapidly replacing traditional hydraulic braking systems across industries.

At the core of these breakthrough actuators is a familiar hero in our world: the ball screw. Here at Helix, we’re not just watching this transformation—we’re manufacturing it.

Why Electro-Mechanical Brake Actuators Are the Future

Whether it’s an electric vehicle, an autonomous off-road machine, or an aircraft system, modern braking requires precise, responsive, and clean solutions. The electro-mechanical brake actuator delivers exactly that—without the mess and complexity of hydraulics.

Instead of brake fluid, EMBAs rely on:

• A compact electric motor
• A gear train
• And most importantly, a ball screw to translate rotary motion into high-force linear actuation

This direct-drive solution is cleaner, lighter, more efficient, and far easier to maintain. And it unlocks a new era of intelligent braking.

How Ball Screws Drive Electro-Mechanical Brake Actuators

At Helix, we design and manufacture custom ball screws specifically engineered for electro-mechanical brake actuator systems. These aren’t off-the-shelf components—they’re precision-engineered solutions built to meet rigorous performance and environmental requirements.

Why are ball screws ideal for EMBAs?

• High mechanical efficiency (up to 90%)
• Low backlash for ultra-precise braking force
• Compact and lightweight without sacrificing thrust
• Durable under high cycle loads
• Minimal maintenance and lubrication needs

Our ball screws are engineered to perform flawlessly through millions of braking cycles, even in the harshest environments.

Industry Applications We're Supporting at Helix

The beauty of this technology is how versatile it is. Here’s where we’re seeing major traction for electro-mechanical brake actuators—and how Helix is supporting each:

• Automotive & EV
  Modern electric vehicles demand smart, fluid-free, by-wire braking systems. We’re supplying custom ball screws to Tier 1s and system integrators building compact, high-force actuators at the wheel-end. These solutions integrate with regenerative braking and deliver precise, instant response—all powered by Helix’s engineering.
  
  
• Off-Road & Industrial Equipment
  Think construction equipment, mining trucks, and autonomous ag vehicles. These machines require sealed, rugged systems that can survive mud, heat, and vibration. Our custom-coated, corrosion-resistant ball screws are a perfect fit for off-road EMBAs that must perform in extreme duty cycles.
  
  
• Aerospace & UAV
  In aerospace, every ounce counts. Our lightweight, high-performance ball screws are being used in brake actuator systems for unmanned aerial vehicles (UAVs) and other flight-critical systems, where redundancy, precision, and weight savings are key.

Cost, Maintenance & Safety: A Triple Win

Let’s talk value. Here’s why manufacturers across industries are turning to electro-mechanical brake actuators—and Helix ball screws to power them:

• Lower Total System Cost
• No hydraulic pumps, hoses, or fluid handling = fewer parts, less weight, and simplified assembly
• Lower Maintenance
• Helix ball screws are built to last—offering long service life with minimal lubrication. No leaks. No bleeds. No hassle.
• Increased Safety

Because EMBAs are digitally controlled, they provide faster response, smarter diagnostics, and fail-safe redundancy. And our precision-engineered ball screws ensure that braking force is delivered exactly when and how it’s needed.

Helix Is Building the Future

This is more than a trend—it’s a transition. At Helix Linear, we’re proud to be designing and manufacturing the ball screw technology that makes this shift possible. Our U.S.-based team works hand-in-hand with engineers across industries to develop custom linear motion solutions that meet real-world application demands.

If you’re designing an electro-mechanical brake actuator, we’d love to collaborate. Our engineers are ready to help you build a safer, smarter, and more efficient braking system—with the performance and reliability that only a Helix ball screw can deliver.

Let’s build the future of motion control—together.

– Chris Nook
    CEO, Helix Linear Technologies