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Re: How to cut spur gears?
The traditional method of cutting standard spur gears uses a rack cutter which translates across the gear faces, in combination with precise intermittent rotation of the gear.
An extension of that is the gear hob, which is like taking a rack, and rotating it about an axis, and translating it some distance along the same axis—you get a helix. That helix is subdivided into cutting faces, which shape the gear teeth. The motion can be continuous: rotation of the gear, and translation of the hob.
Gear shapers are a form of tooth cutting used for internal gears, where a hob wouldn't fit.
You can also grind teeth, with precision wheels, profiled to match the desired tooth form.
You might be able to make one of these methods work, with the right tooling, but the tooling (and the fixture to hold it) would be messy and expensive. I'd just send it out for wire EDM cutting instead, if that's available.
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