How We Fabricated a Custom Elevator Brake Arm to Save Time and Money

When a client came to us needing a specific elevator brake arm, they faced a major hurdle: the only option available online required a minimum order of 200 pieces. But all they needed was a single replacement part. Instead of paying for more than they needed and facing lengthy delays, we stepped in to fabricate a custom elevator brake arm, saving them both time and money. Here’s how we approached the project, from material selection to final testing, ensuring the part met all necessary specifications and performed flawlessly.

Step 1: Understanding the Requirements

Before diving into fabrication, it’s essential to understand the specific requirements for the elevator brake arm. This involves assessing factors like strength, durability, and compatibility with the existing elevator system. Given the brake arm’s role in safely stopping an elevator, it must be able to withstand significant stress and function flawlessly under high loads.

Step 2: Selecting the Right Material

The material selection is a critical step. We chose 1018 cold finished steel for its excellent combination of strength, durability, and machinability. This material is commonly used in high-stress applications like elevator components, making it an ideal choice for our custom brake arm.

Step 3: Machining the Brake Arm

Once we had the design and material sorted, we moved on to machining the brake arm. This process involved several key steps:

• Milling the steel to shape the brake arm according to the sample we were replicating.
• Drilling the rim for precision and ensuring compatibility with the system.
• Inserting a bronze sleeve to improve friction resistance and provide a smoother operation.
• Fabricating a new shaft to complete the assembly.

Throughout the machining process, we focused on ensuring the part’s precision and structural integrity.

Step 4: Overbuilding for Durability

To ensure the brake arm could withstand the high pressures it would face in service, we decided to overbuild the part. By adding extra strength and reinforcement, we made sure the brake arm would handle even more stress than required, adding an extra layer of safety and reliability to the design.

Step 5: Testing for Quality Assurance

With the brake arm fabricated, the next step was rigorous testing. We conducted several tests, including:

• Stress analysis to evaluate the material’s response to pressure.
• Load testing to ensure the brake arm could handle the elevator’s braking requirements.
• Operational simulations to verify the arm’s functionality under real-world conditions.

These tests were crucial in confirming the part’s durability and performance.

Step 6: Installation and Ongoing Maintenance

Once the brake arm passed all quality checks, it was ready for installation in the elevator system. It’s important to note that installing the brake arm requires a qualified technician to ensure it meets all safety standards and functions as expected. Even after installation, regular maintenance and inspections are essential to keep the brake arm—and the entire elevator system—operating smoothly. This includes checking for wear, ensuring proper lubrication, and replacing any parts that show signs of fatigue.

Why Custom Fabrication Makes Sense

In situations like this, custom fabrication can save time, money, and hassle. Rather than waiting for a large order of parts, we were able to provide the client with exactly what they needed, without the unnecessary expense of excess inventory. Custom fabrication also allows us to tailor the part to meet the exact specifications required, ensuring optimal performance and longevity.

Conclusion

By fabricating a custom elevator brake arm from scratch, we were able to provide our client with a cost-effective, high-quality solution that met their needs and saved them from unnecessary delays. Whether you need a one-off replacement or a small batch of parts, custom fabrication offers flexibility, precision, and reliability—ensuring your elevator system operates safely and efficiently.