Why DIY Motion Base Platforms Aren’t as Simple (or Safe) as They Seem

In my time exploring the internet, I’ve come across countless DIY motion base projects—built from everything from drill motors to plywood. While many of these builds are undeniably creative, they often raise serious concerns about safety, longevity, and performance. Let’s take a closer look at why building a motion base platform isn’t as straightforward as it might seem.

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What Does It Really Take to Build a Motion Base?

At the most basic level, a motion base needs actuation—something to move each axis. This is typically achieved using:

Hydraulic systems (powerful but complex and messy)

Pneumatic systems (hard to control precisely and very loud)

Magnetic systems (not ideal for load-bearing)

Electric motors (the most practical for DIYers)

Electric motors are the go-to for most hobbyists, but even here, the choices are far from simple.

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Choosing the Right Motor: AC vs. DC

DC motors are easier to control and integrate into servo systems but can be expensive (excluding steppers).

AC motors require more advanced knowledge to achieve full torque at zero RPM—something even seasoned engineers find challenging.

Most DIYers avoid AC motors for this reason. And many don’t even implement a servo loop, which is essential for accurate motion control.

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Linear vs. Non-Linear Motion

Once you’ve selected a motor, the next decision is how to translate that motion:

Linear systems (e.g., screw drives) are simpler but prone to wear and chatter due to bearing degradation.

Non-linear systems (e.g., crank and pushrod) are more complex to design but offer smoother, longer-lasting performance—ours have lasted decades.

Regardless of the method, you’ll need a gearbox matched to your motor and payload to ensure proper torque and motion fidelity.

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Servo Loops: The Heart of Motion Control

To control motion accurately, you need to know:

Where the motor is

How fast it’s moving

How to adjust its position in real time

This is where the servo loop comes in. It requires:

A motor drive amplifier

A feedback device (like an encoder)

A control signal (analog or digital)

Without this loop, your motion base won’t respond accurately—or safely.

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Control Systems and Software Complexity

Controlling the motor depends on your amplifier and interface. Options range from:

Computers with DAC boards

PLCs

Signal generators

The higher the resolution, the better the response. But even with good hardware, you’ll likely need to write custom software to interface with simulation platforms like X-Plane, MSFS, or Prepar3D.

And it’s not just about connecting the software—it’s about modeling the physics. Aircraft and vehicles have different centers of gravity and motion profiles. If your system is non-linear, your software must account for that too. This adds significant complexity.

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Mechanical Design and Geometry

You’ll also need to design:

A rigid frame to mount motors and actuators

A top platform to carry the payload

Geometry that supports the desired angularity and range of motion

You must calculate center of gravity, overhung loads, and structural tolerances to ensure the system can move safely and accurately.

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The Hidden Cost: Time and Labor

Even if you source parts affordably, the real cost is in the engineering, fabrication, wiring, testing, and tuning. Most DIYers don’t account for their time because it’s a hobby—but if it takes a year to build, that’s a year of unpaid labor.

For professionals like us, this isn’t a hobby—it’s a business. And with that comes the responsibility to ensure safety, reliability, and performance. If we get it wrong, someone could get hurt—or worse.

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So, Can You Build a Motion Base for $5,000?

Short answer: No.

$5,000 per axis? Possibly—if it’s a basic design.

A standard 6DOF motion base (just the platform and electronics, not including the controller or software) for a single rider (~500 lbs) with ±15° roll and pitch typically starts around $30,000.

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What to Watch Out For

If you’re considering a motion base system that costs less than $5,000 per axis, ask the manufacturer:

Can they provide structural and design analysis?

What is the mean time between failure?

How long have they been in business?

Do their designs resemble those of long-established companies?

If they can’t answer—or if their designs look suspiciously familiar—they may not be offering original, engineered solutions.

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Final Thoughts

Designing a motion base platform is a complex, multidisciplinary engineering challenge. It involves mechanical, electrical, and software integration at a high level. That’s why these systems are expensive—and why they should be.

At Servos & Simulation, we’ve been building motion platforms for over 40 years. We have the documentation, the photos, and the experience to back it up. If you’re serious about simulation, we’re here to help you do it right.