Introduction: Linear and Rotary Actuator
This Instructable is about how to make a linear actuator with a rotatable shaft. This means you can move an object forwards and backwards and rotate it at the same time. It is possible to move an object 45 mm (1.8 inch) back and forth and rotate it 180 degrees.
The costs are approximately $50. All the parts can be either 3D printed or bought in a hardware store.
The used motors are two commercially available servo motors. Beside the low price servos have a useful characteristic: Servos do not need any additional control logic. In case you are using an Arduino  and its Servo library , the writing of a value between 0 and 180 is directly the position of the servo motor and in our case the position of the actuator. I only know the Arduino but I am sure on other platforms it is also very simple to control servos and hence this actuator.
To build it you need a standing drill machine and a 4.2 mm metal drill. You are going to drill out M4 nuts to be your sleeve bearings.
Further you need a good bench vice and a screw die to cut a M4 thread on a metal rod. For the fixation of the rods a M4 screw tap is required.
1 Standard Servo Tower Pro MG946R. Comes with servo arm, 4 M2 mounting screws and 4 d3 brass hulls
1 Micro Servo Tower Pro MG90S. Comes with servo arm and 2 mounting screws
11 M2 x l10 mm flat headed screw
4 M4 washer
6 M4 nut
1 Snap ring d4 mm
1 Paperclip d1 mm
1 Wooden dowel d6 x l120
2 Steel or aluminum rod d4 x l166 with M4 x l15 thread on one end
1 Steel or aluminum rod d4 x l14 with a snap ring notch
1 Steel or aluminum rod d4 x l12
Legend: l:length in millimeters, d:diameter in millimeters
Step 1: 3D Printed Parts
You either need to print the left-sided or right-sided parts. The pictures in this Instructable show a left-sided LnR Actuator (Looking from the front, the wooden dowel is on the left side).
If you do not have a 3D printer, I recommend looking for a 3D printing service nearby.
Step 2: Slider Bearings
As bearings, the M4 nuts are used! For that, you drill out the (M4/3.3 mm) holes with the 4.2 mm metal drill. Press the drilled out M4 nuts into the openings in the slider.
Glue 2 M4 washers onto the slider and the slider top.
Step 3: Mirco Servo and Extension Arm
Mount the Micro Servo onto the slider.
On the right side you see the extension arm and the remaining 2 M4 nuts. Press the drilled out M4 nuts into the openings of the extension arm.
Step 4: Slider and Rotateable Shaft
Assemble slider, extension arm and slider top. Use the small 12 mm long metal rod as the axis.
At the bottom of the picture you see the flange that is attached to the Micro Servo arm.
You need to drill a 1.5 mm hole into the wooden dowel (bottom right of the picture), otherwise the wood will break.
Step 5: Servo Joint
Drill a 4.2 mm hole into the standard servo arm and add a notch to the 14 mm metal rod for the snap ring.
Glue one of the washers onto the servo arm.
This is how you stack the components from top to bottom:
1) Mount the snap ring onto the axis
2) Add a washer
3) Hold the servo arm under the extension arm and press the assembled axis through it.
4) Add some glue to the fixation ring and press it from the bottom onto the axis.
The picture is not up-to-date. Instead of the second snap ring it shout show the fixation ring. The idea with the fixation ring is an enhancement to the original design.
Step 6: Servo Mount
The standard servo is attached to the actuator. In order to bring the servo through the opening, you need to remove its bottom cap so you can bend the cable down.
The mounting screws go into the messing hulls first, then through the holes in the actuator. Drill the screws into the fixation blocks which are put below the LnR-Base.
Step 7: Longitudinal Motion
With the M4 screw tap you cut a thread into the 3.3 mm holes of the back plane of the LnR-Base.
The slider move on the two metal rods. These are pushed through the 4.2 mm front holes of the LnR-Base, then through the slider bearings and fixated with the M4 thread in the back plane of the actuator.
Step 8: Cover
That is the LnR Actuator!
To fix the Micro Servo cable, a part of a paper clip is used. Mount the hood onto the actuator and you are done.
Step 9: Arduino Sketch (optional)
Connect two potentiometers to the Arduino inputs A0 and A1. The signal pins are 7 for rotary and 8 for longitudinal motion.
It is important that you take the 5 Volts from the Arduino for the potentiometers and not from the external 5 V power supply. To drive the servos you have to use an external power supply.
Step 10: Beyond a Programming Example (optional)
This is how I cancel systematic errors in the software that controls the LnR Actuator. By eliminating the positioning error due to mechanical transformation and due to mechanical play, a positioning accuracy of 0.5 millimeters in longitudinal direction and 1 degrees in rotary motion is possible.
Mechanical transformation: Arduinos map function  can be written as: f(x) = a + bx. For the demo data set , the maximum deviation is 1.9 mm. This means at some point, the position of the actuator is almost 2 millimeters away from the measured value.
With a polynomial with a degree of 3, f(x) = a + bx + cx^2 + dx^3, the maximum deviation for the demo data is 0.3 millimeters; 6 times more accurate. To determine the parameters a, b, c and d, you have to measure at least 5 points. The demo data set has more than 5 measurement points, but 5 are sufficient.
Mechanical play: Due to the mechanical play, there is an offset in the position if you move the actuator first forwards and then backwards, or if you move it clockwise and then counter clockwise. In the longitudinal direction, the actuator has mechanical play in the two joints between the servo arm and the slider. For the rotary motion, the actuator has mechanical play between the slider and the shafts. The servo motors have also some mechanical play themselves.
To cancel the mechanical play, the rules are:
A) When moving forwards or clockwise, the formula is: f(x) = P(x)
B) When moving backwards or counter clockwise, the formula is: f(x) = P(x) + O(x)
P(x) and O(x) are polynomials. O is the offset that is added due to the mechanical play. To determine the polynomial parameters, measure 5 points when moving in one direction and the same 5 points when moving in the opposite direction.
If you are planning to control multiple servo motors with an Arduino and I convinced you to do a software calibration using polynomials, have a look at my prfServo Arduino library .
For the pencil lead drive video the prfServo library was used. For each of the four servos a five point calibration was done in both directions.
Other systematic errors: The actuator has additional systematic errors: Friction, eccentricity and the resolution of the used servo library and servo motors.
Maybe, more as a fun fact, the resolution of the Adafruit Servo Shield  is 0.15 mm in longitudinal direction! Here is why: The servo shield uses the PCA9685 chip to produce the PWM signal. The PCA9685 is designed to create PWM signals between 0 and 100 % and has 4096 values for that. But for a servo, only values of lets says 200 (880 μs) to 500 (2215 μs) are used. 45 mm hub divided by 300 is 0.15 mm. If you do the math for the rotary motion, 180º divided by 300 points is 0.6º.
Step 11: References
 Arduino: https://www.arduino.cc/
 Servo library: https://www.arduino.cc/en/reference/servo
 Adafruit ServoShield: https://www.adafruit.com/product/1411
 prfServo library: https://github.com/mrstefangrimm/prfServo
 Arduino map function: https://www.arduino.cc/reference/en/language/funct...
 Example data set: