Gorial, I. (2025). A review of smart actuation technologies in modern mechatronic systems. , 43(8), 670-682. doi: 10.30684/etj.2025.158859.1933
Ivan I. Gorial. "A review of smart actuation technologies in modern mechatronic systems". , 43, 8, 2025, 670-682. doi: 10.30684/etj.2025.158859.1933
Gorial, I. (2025). 'A review of smart actuation technologies in modern mechatronic systems', , 43(8), pp. 670-682. doi: 10.30684/etj.2025.158859.1933
Gorial, I. A review of smart actuation technologies in modern mechatronic systems. , 2025; 43(8): 670-682. doi: 10.30684/etj.2025.158859.1933

A review of smart actuation technologies in modern mechatronic systems

Engineering and Technology Journal
Volume 43, Issue 8, August 2025, Pages 670-682    PDF (1.26 M)
Document Type: Review Paper
DOI: 10.30684/etj.2025.158859.1933
Author
Ivan I. Gorial*
Control and Systems Engineering Dept., University of Technology-Iraq, Alsinaa street, 10066 Baghdad, Iraq.
Abstract
Smart actuation has transformed mechatronics over the past six years by harnessing materials that turn heat, electricity, magnetism, or light into finely tuned motion. Our survey of developments from 2019 to 2025 reveals clear trade-offs: electro-active polymers can stretch beyond 200% but operate at roughly 30% efficiency, whereas piezoelectric devices achieve over 95% efficiency with displacements under 0.1%. Ionic polymer–metal composites and magnetorheological actuators strike the best balance for precision work, delivering about 50% stroke at 60% efficiency. Real-world examples show that packing tiny shape-memory alloy bundles into soft exosuits grants sub-millimeter accuracy without sacrificing comfort, and that materials capable of reversing energy flow and monitoring their state greatly improve closed-loop control and fault detection. We examine control methods—from model-predictive to adaptive schemes alongside scalable fabrication routes spanning 3D (Three-Dimensional) printing to microfabrication, and identify lingering challenges in manufacturing scale-up and high-frequency response. Looking forward, embedding computation within actuator materials, adding artificial intelligence-driven adaptability, combining multiple stimuli in hybrid designs, and harvesting energy internally promise to usher in truly autonomous, life like mechatronic systems. This review outlines recommendations to advance energy-efficient, sustainable actuator designs. It highlights the importance of multidisciplinary collaboration among materials engineers, system designers, and control experts to accelerate real-world deployment.

Highlights
  • This review covers smart actuator advancements in mechatronic systems from 2019 to 2025.
  • Actuators are grouped by stimulus type and material class, such as SMAs, hydrogels, and nanomaterials.
  • Applications include soft robotics, biomedical tools, and smart manufacturing systems.
  • Smart materials enable accurate motion and force control in modern mechatronic systems.
  • Actuator fabrication and control system integration methods are analyzed in detail.
Keywords
Smart actuators; Mechatronics; Soft robotics; Actuator control; Smart materials; Shape memory alloys
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