This paper investigates an improved sliding mode variable structure control method for hypersonic vehicle actuators. To overcome the control challenges in extreme flight conditions, especially maintaining actuator fidelity at high speeds, a sliding mode control (SMC) strategy with an extended state observer (ESO) is proposed. To address issues of chattering and finite-time convergence in traditional SMC, a novel nonsingular terminal sliding mode surface and reaching law are designed. The ESO estimates external load disturbances, which are compensated within the control loop. A variable boundary layer saturation function is also introduced to further suppress chattering. Experimental results confirm the proposed method’s strong robustness and disturbance rejection, demonstrating its effectiveness in practical applications.