Cooling optimisation for a robotic actuator combining motor, gearbox and electronics in a compact housing was performed using CFD coupled to thermal FEM methods. CFD modelling of airflow through the inlet, fan and cooling channels was used to calculate flow velocity distribution and heat transfer coefficients. Steady state and transient thermal analyses were performed using dissipation data reproducing typical legged robot application.  The work resulted in redesign solutions which were implemented to improve heat transfer and components cooling performance.