Design of high speed hydraulic cylinder cushioning is significant and is employed in many defence and non-defence applications. In one such defence application, high-speed hydraulic actuator is used for operation of specially designed mechanism. Cushioning in such high-speed operations coupled with heavy mass is very critical and is a complicated non-linear dynamic problem to analyse. This paper brings out the cushioning design carried out for this hydraulic actuator using some unconventional cushion spear shapes. Multi-body dynamic (MBD) modelling, simulation and analysis of the unconventional cushioning is carried out using a Computer Aided Engineering (CAE) tool SimulationX, which is a high-end MBD tool for simulating non-linear, dynamic effects. Further, the performance characteristics using different cushion piston design are obtained and compared to analyse the results. Based on this, the better design is suggested. The paper also brings out the design efforts carried out for challenges faced in terms of mechanism design and space management.