Involute Gear Pair

Print Zero - Gear Set

Tools used to design these
1. Gear Generator (http://woodgears.ca/gear_cutting/template.html)
2. 3DS Max

Steps:
1. Create desired gear in Gear Generator and export as DXF Polylines

2. Import the DXF in 3DS Max, extrude the spline to desired thickness.
Extrusion is a bit tricky due to absence of vertex with index 1. Therefore switch to the
vertex edit mode for the editable spline, select the inner shaft vertices and delete, select a random vertex on the teeth spline and click on Make First, create a circle in the center and attach to the outer spline, the circle diameter will be the shaft diameter, then extrude using the modifiers stack, convert to Editable Poly and then extrude to the desired thickness. More on this coming up soon on my blog.

3. Export as STL.
4. Print