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Flight control systems of civil aircraft have undergone huge developments in the last decades. The current more/ all electric aircraft concepts lead to the replacement of the hydraulic actuators in the primary flight control systems by electromechanical systems. Integrating electromechanical systems in safety critical applications implies three main challenges: (a) the detection of all fault cases which could lead to a safety critical state, (b) finding measurement parameters capable to detect faults, and (c) the development of algorithms to detect faults under all flight conditions. Putting the scope on the health monitoring of the mechanical components of a direct drive actuator, a new technology based on piezoresistive thin film sensors (TFS) is presented and its potential shown by using defective ball bearings as an example.