Reengineering a Failed Drive Gear for an ADA Vehicle Lift

A recent project involved reproducing a failed drive gear from an ADA vehicle lift used by a disabled individual. The original component had failed after years of service, leaving the equipment inoperable and replacement parts difficult to source.

Rather than simply duplicating the original design, the goal was to understand why the failure occurred and develop a replacement that improved durability while maintaining full compatibility with the existing assembly.

The project included:
• Reverse engineering the original gear geometry
• Creating a production-ready CAD model
• Evaluating material options
• Optimizing the design for improved durability and manufacturability

The final component was manufactured from an upgraded engineering material selected to improve wear resistance while maintaining compatibility with the existing assembly.

Projects like this help extend the service life of existing equipment when replacement components are no longer available or can be improved through modern engineering and manufacturing methods.

At Gaines Design, we help manufacturers, machine shops, and equipment owners transform legacy components into production-ready engineering solutions.