Question 1

What is a pancake pneumatic cylinder?

Accepted Answer

A pancake pneumatic cylinder (also called a flat cylinder or low-profile cylinder) is an ultra-thin actuator designed to produce pneumatic force and short-stroke motion in applications where the available height or depth is extremely limited. The pancake design achieves the thinnest possible profile by minimizing the space between the mounting face and the end of stroke — the collapsed height is barely more than the piston thickness plus the end caps. Despite their flat shape, pancake cylinders generate the same force as any cylinder of the same bore size at the same pressure. They are typically available in bore sizes from about 1/2 inch to 6 inches with very short strokes (typically 1/4 inch to 2 inches). Pancake cylinders are the go-to choice when the machine design has a severe height restriction but still requires a significant clamping, pressing, or lifting force in that tight space.

Question 2

What applications use pancake cylinders?

Accepted Answer

Pancake cylinders are used wherever the installation space is extremely limited in height or depth. Workholding fixtures use them as the clamping actuator when the fixture design does not allow room for a standard-height cylinder — the pancake cylinder mounts flush in or under the fixture plate and pushes up through the plate to clamp the workpiece. Transfer press tooling uses them inside the die space for lifting, ejecting, or stripping operations where the vertical space between the press bed and the die is very tight. Conveyor diverters and pop-up stops use them to push a diverting bar or stop pin up through the conveyor surface and retract it flush. Rotary indexing tables use them for clamping or actuating at stations where the space under the table is limited. Door latching and locking mechanisms use them for compact push/pull actuation. The common thread is a severe height constraint combined with a need for short-stroke pneumatic force.

Question 3

What is the difference between a pancake cylinder and a compact cylinder?

Accepted Answer

Both serve short-stroke, space-constrained applications, but they are optimized for different space constraints. Pancake cylinders are specifically designed to minimize height (the dimension along the cylinder axis). Their ultra-flat profile means the collapsed height from the mounting surface to the top of the rod is as thin as physically possible. This makes them ideal when the constraint is strictly vertical clearance — for example, fitting under a fixture plate, inside a press die, or below a conveyor surface. Compact cylinders are designed to minimize overall size in all dimensions — they are shorter than standard cylinders but not as aggressively flat as pancake cylinders. Their square or rectangular body profile with face-mount through-holes is optimized for easy, direct mounting. If the height constraint is moderate and general compactness is the goal, a compact cylinder provides a good balance of small size and easy mounting. If the height constraint is severe and every millimeter of profile height matters, a pancake cylinder's ultra-flat design is the right choice.

Question 4

What bore sizes are available for pancake cylinders?

Accepted Answer

Pancake cylinders are available in a range of bore sizes to provide different force levels in the ultra-low-profile package. Typical bore sizes range from approximately 1/2 inch to 6 inches, with the most common sizes being 1 inch, 1-1/2 inch, 2 inch, 2-1/2 inch, 3 inch, 4 inch, 5 inch, and 6 inch. Force output at 100 PSI ranges from approximately 80 pounds for a 1-inch bore to over 2,800 pounds for a 6-inch bore. Strokes are intentionally short — typically 1/4 inch to 2 inches — to maintain the low profile. Most pancake cylinders are double-acting. Mounting is usually through bolt holes in the face or body for direct attachment to the fixture or machine surface. Some models are available with built-in magnet pistons for external position sensing.

Question 5

What should I consider when selecting a pancake cylinder?

Accepted Answer

Key selection criteria include: Collapsed height — measure the available space and verify the pancake cylinder fits when fully retracted, including the rod end connection and any tooling attached to the rod. Force requirement — select the bore size that provides the needed force at your air supply pressure, with a safety factor. Stroke — verify that the available stroke is sufficient for the clamping, lifting, or ejecting distance needed. Mounting — confirm the bolt pattern and mounting surface are compatible with your fixture or machine. Rod end connection — verify the thread type and size for attaching to your tooling or clamp pad. Operating pressure — ensure the cylinder is rated for your system pressure. Duty cycle — if the application involves very high cycle rates, confirm the cylinder is rated for the expected duty. Because pancake cylinders prioritize low profile over all other characteristics, they may have trade-offs in stroke length and mounting flexibility compared to other cylinder types.

Pancake Cylinders - Fabco-Air

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