How do I make sure two gears generated here will mesh together?

Two gears will mesh perfectly as long as their Module (m = Pitch Diameter L ÷ Tooth Count H) is identical. For example, Gear A with L=96mm and H=24 teeth has Module m = 4.0. Gear B with L=48mm and H=12 teeth also has Module m = 4.0. Mount their centers at (96 + 48) / 2 = 72.0mm apart.

What is the best plastic to laser-cut mechanical gears from?

Delrin (Acetal / POM) is the gold standard for laser-cut gears because it has a low coefficient of friction, high wear resistance, and cuts cleanly on a CO2 laser without melting. Cast acrylic looks great for display gears but is brittle under high torque.

Why is the Pitch Circle drawn on the Blue CREASE layer?

The Pitch Circle represents the theoretical contact diameter where two mating gears roll against each other. Placing it on the Blue CREASE/Reference layer lets you check shaft alignment in CAD while ignoring it during through-cutting.

Are both the outer gear teeth and center shaft hole closed polylines?

Yes, both the external gear tooth perimeter and the internal shaft bore are exported as 100% closed LWPOLYLINE loops on the CUT layer.

TEMPLATE ID: PRE-MEC-007 90 × 20 × 36 mm (T=5mm) Pre-Verified 1:1 Static Files Ready

36-Tooth Heavy-Duty Involute Spur Gear Wheel (Ø90mm Pitch Diameter, Module 2.5, Ø20mm Bore)

Interactive Parametric 2D & 3D Studio

Live 2D Dieline, Interactive 3D Fold Preview & Custom Size Generator

Pre-loaded with 36-Tooth Module 2.5 Spur Gear (90×20×36 mm, T=5mm)

1:1 CAD ENGINE READY

36-Tooth Heavy-Duty Involute Spur Gear Wheel (Ø90mm Pitch Diameter, Module 2.5, Ø20mm Bore)

1CAD Style & Material SetupMechanical

Select CAD Style / Model (36)Search & Filter

Material Stock Preset (Auto-Sets Caliper T & Kerf K)

Display Units

Scale Lock

1:1 True Scale

2Dimensions (1:1)Millimeters (mm)

Pitch Diameter (D_p mm)90 mm

Center Shaft Bore (Ø mm)20 mm

Number of Teeth (Z / N)36 teeth

Thickness (T mm)

Laser Kerf (K mm)

3Brand Logo & 1:1 ExportZero Login

2D & 3D Brand Logo Mockup:

📤 Upload Logo

Print Artwork Bleed Guide:

Embed Spec Sheet & 50mm / 1" Scale Bars (Added on separate DIMENSIONS layer)

Pre-Flight Geometry Audit8/8 PASSED

PASS
Closed Outer Contours: 2 closed LWPOLYLINE cut loop(s) verified
PASS
Zero Duplicate Cut Paths: 176 unique segments (0 laser double-burns)
PASS
Flute & Kerf Tolerance Guard: T=5.00mm, K=0.100mm within structural limits
PASS
ISO Layer Color Separation: CUT (Red), CREASE (Blue), SCORE (Emerald), DIMENSIONS isolated
PASS
1:1 Physical Unit Header: Explicit mm/in SVG viewBox + DXF $INSUNITS=4 + 50mm PDF bar
PASS
Exact 2D Cut Bounding Parity: Cut Bounds 94.91×94.91mm === Blank Size
PASS
2D ↔ 3D Kinematic Model Sync: Archetype 'spur_gear_flange' synced (1 3D component(s))
PASS
True Vector Sheet Nesting Sync: 1:1 vector paths mapped to multi-up sheet grid

100%

CUT (0.63m) CREASE/SCORE (0.28m)● 2 Loops · Est. Cut: ~39s

1:1 Synced · Blank: 94.91 × 94.91 mm

2D 1:1 Unfolded Vector BlueprintBlank: 94.91 × 94.91 mm (3.74" × 3.74")

3D Interactive Fold & Orbit (Kraft Board)

288°

0%100%

Camera:

Yaw: -28°Pitch: 24°

⟳ Drag Anywhere to Rotate 3DL=90 × W=20 × H=36mm

Outside Diameter (OD)

95.00 mm

Pitch Diameter (PD)

90.00 mm

Gear Module (m)

2.500 mm

Tooth Count (Z)

36 Teeth

Direct Pre-Generated 1:1 CAD Files

Download Static Ready-to-Cut Files (90×20×36 mm)

These static files are pre-calculated for 5mm material thickness and 0.1mm laser kerf. Click any format below to download the pre-built static file, or export custom dimensions directly from the interactive Studio above.

↓ Download .DXF AutoCAD / LightBurn ($INSUNITS=4) ↓ Download .SVG Illustrator / Corel (1:1 mm) ↓ Download .PDF 1:1 Print + 50mm Scale Bar

Product Manufacturing Specification Sheet

Calibrated Physical Clearances & Material Stock for 36-Tooth Module 2.5 Spur Gear

Parent Parametric Engine: Involute Spur Gear CAD →

Target Physical Product Size

ISO 53 Module m = 2.5 mm, Z = 36 Teeth, Pitch Circle Ø90.0 mm, Outside Tip Ø95.0 mm

Engineered Internal Cavity & Clearance

20° Pressure Angle Involute Flanks + Ø20.0 mm Central Shaft Bore

Recommended Board / Sheet Stock

5.0mm–6.0mm Delrin (POM), Baltic Birch Plywood, or Mild Steel Plate

Grain / Flute Orientation Rule

Isotropic Sheet Stock

Production Engineering Note: Meshes smoothly with our 18-Tooth (Ø45mm) or 24-Tooth (Ø60mm) Module 2.5 spur gears.

Structural Geometry & Material Reference (ISO 53 / DIN 867 Metric Gear Profile Standard)

Designing a functional mechanical spur gear for laser cutting, CNC routing, waterjet, or 3D printing requires strict adherence to ISO 53 gear geometry where the Pitch Diameter (D_p), Tooth Count (Z), and Metric Module (m = D_p / Z) govern tooth meshing. Two gears will only mesh smoothly if they share the exact same Module (m) and Pressure Angle (20 degrees), with their center-to-center shaft distance set to (D_p1 + D_p2) / 2. Our parametric CAD engine generates a 100% closed outer tooth profile (`CUT` layer), concentric center shaft bore (`CUT` layer), and reference Pitch Circle (`CREASE` layer).

Metric Gear Module (m)

m = Pitch_Diameter (L) / Tooth_Count (H)

Fundamental tooth size index in millimeters. Two mating gears MUST have the exact same Module (m).

Outside Tip Diameter (OD / Addendum Circle)

OD = Pitch_Diameter + 2 * m = m * (Z + 2)

Adds one module (1.0 * m) of addendum height to each side of the pitch circle.

Root Dedendum Diameter (D_root)

D_root = Pitch_Diameter - 2.5 * m

Provides 1.25 * m root depth (including 0.25 * m bottom clearance) so mating gear tips never bottom out.

Internal CAD Silo & Related Ready-to-Cut Templates