Gears · Laser Generator Studio
Laser Cut Gear Generator
Involute spur gears, meshing pairs and racks that actually run smoothly, with the ratio and centre distance worked out, backlash for laser-cut parts, and round, D-flat or keyed bores.
- Exports
- SVG, DXF, PDF, EPS
- Works with
- LightBurn, xTool Creative Space, Glowforge, CAD and CNC software
- Materials
- Plywood, acrylic, MDF, hardboard
What it makes
The Gears studio draws involute spur gears, the tooth shape used in real machinery, because it keeps the gears rolling smoothly and at a constant speed as the teeth mesh. Make a single gear, a meshing pair or a gear and rack, with the ratio and centre distance calculated for you. Laser-cut gears drive clocks, automata, marble machines, kinetic sculptures, educational models and toys.
The numbers that matter
| Setting | What it does |
|---|---|
| Module | Tooth size. Gears must share the same module (and pressure angle) to mesh |
| Teeth | Number of teeth on gear A and its partner; sets the ratio |
| Pressure angle | Tooth profile angle; 20° unless a gear has fewer than about 12 teeth |
| Backlash | Deliberate play between teeth; 0.1 to 0.2 mm suits laser-cut parts |
| Bore | Round, D-flat or keyway, to match your shaft |
| Spokes | Lightening cut-outs that save material and weight |
Ratio and centre distance
The ratio is the tooth count of the driven gear divided by the tooth count of the driving gear: a 12-tooth gear driving a 36-tooth gear turns the big gear once for every three turns of the small one, with three times the torque. The studio shows the ratio and the exact centre distance for any pair. Mount the shafts at that distance; it is the single most important measurement in a gear train.
Making laser-cut gears run well
- Add backlash. 0.1 to 0.2 mm stops laser-cut teeth binding.
- Fit the bore to the shaft. Laser holes come out slightly larger than drawn by about the kerf. Measure your kerf and adjust the bore for a snug fit on dowels, rods or bolts.
- Thicker gears, steadier mesh. 3 mm parts work for light models; stack two layers or use 6 mm for anything carrying load.
- Keep teeth clean. A light sand removes char that adds friction, and wax helps wooden gears run smoothly.
Acrylic or plywood? Clear acrylic shows the mechanism, which suits display pieces and clocks, but it needs a CO₂ laser. Birch plywood is tougher and cuts on diode lasers too. See the acrylic and wood guides.
Beyond spur gears
For moving mechanisms such as Geneva drives, cams and followers, a clock escapement, ratchets and timing pulleys, the Mechanisms & Automata studio in the app builds on the same principles. Gear trains often live in a frame or enclosure: the box generator makes one with finger joints, and living hinges make curved housings.
Export
Gears export as SVG for laser software and as DXF for CAD and CNC, in millimetres, so the geometry stays exact when you bring it into a larger design.
Questions
What is a gear's module?
Module is the tooth size in millimetres: pitch diameter divided by the number of teeth. Two gears only mesh if they have the same module and pressure angle.
How far apart do the shafts go?
The studio shows the centre distance for the pair. Place the shafts exactly that far apart; too close and the gears bind, too far and the teeth skip.
Why add backlash?
Laser-cut teeth are never perfect, and wood swells. A little backlash, about 0.1 to 0.2 mm, leaves enough play for the gears to turn freely without binding.
Which pressure angle should I use?
20 degrees, the modern standard, unless a gear needs fewer than about 12 teeth.
What material is best for laser-cut gears?
Birch plywood and acrylic are the usual choices. Acrylic runs smoothly and looks good in display pieces; plywood is tougher and easier to glue to shafts.
xTool, LightBurn, Glowforge are trademarks of their respective owners. Laser Generator Studio is an independent product and is not affiliated with or endorsed by them.