Current gait rehabilitation systems have limited use in community and home settings due to issues of design, cost, and demands on clinical staff. To overcome these challenges, a new gait rehabilitation machine was designed and developed by modifying an existing elliptical trainer. The Intelligently Controlled Assistive Rehabilitation Elliptical (ICARE) provides answers to design limitations that occur in partial-bodyweight-support treadmill systems and other robotic systems by providing a simulated gait motion without the financial and human resource challenges. The ICARE system integrates ergonomic, comfort and safety enhancements with a motor-drive system to optimize usability by individuals with physical disabilities in hospitals, homes, and fitness settings. The affordable new design provides a complete system that reduces physical demands on clinical staff without compromising patient safety. Development and preliminary testing of the ICARE’s motor-drive system are detailed.