Measure existing gears and use these parameters to create 3D model in CAD in the way as above. This is more easy than in previous steps, but also required to find similar gears (or at least their picture) Use graphics software with build in gear generation features. It allows to generate 2D geometry of gears and export it to dxf file PTC Creo Elements/Direct Modeling Express 6 this is free software which allows to create quick and easy mechanical models for prototypes.
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