The growing global demand for energy and environmental implications have created a need to further develop the current energy generation technologies (solar, wind, geothermal, etc.). Recovering energy from low grade energy sources such as waste heat is one of the methods for improving the performance of thermodynamic cycles. The objective of this work was to achieve long-term steady state operation of a Free-Piston Linear Expander (FPLE) and to compare the FPLE with the currently existing expander types for use in low temperature energy recovery systems. A previously designed FPLE with a single piston, two chambers, and linear alternator was studied and several modifications were applied on the sealing and over expansion. An experimental test bench was developed to measure the inlet and outlet temperatures, inlet and outlet pressures, flow rate, and voltage output. A method of thermodynamic analysis was developed by using the first and second law of thermodynamics with air as the working fluid. The experimental tests were designed to evaluate the performance of the FPLE with varying parameters of inlet air pressure, inlet air temperature, and electrical resistance. The initial and steady-state operation of the FPLE were successfully achieved. An uncertainty analysis was conducted on the measured values to determine the accuracies of the calculated parameters. The trends of several output parameters such as frequency, average root mean square (RMS) voltage, volumetric efficiency, electrical-mechanical conversion efficiency, isentropic efficiency, irreversibility, actual expander work, and electrical power were presented. Results showed that the maximum expander frequency was found to be 44.01 Hz and the frequency tended to increase as the inlet air pressure increased. The FPLE achieved the maximum isentropic efficiency of 21.5%, and produced maximum actual expander work and electrical work of 75.13 W and 3.302 W, respectively.