Steps:

>Run "keygen" with admin rights.

>Enter the registeration details
>Click "Apply Registration" and browse "GearGenerator3.exe" file.
>If you like it, buy it.
Things that the gear template generator can do:
>Involute spur gears (spur, ring, and rack)
>Planetary gear sets (using ring gears)
>Calculate small gear tooth undercut shapes
>Latntern / cycloid gear pairs
>Block chain and roller chain sprocket calculations
>Print gears across multiple pages
>Show grids with diagonals to help align multi-page printouts
>Support for metric and inches dimensions
>No internet connection required
>Export DXF, HPGL, CSV, Sketchup, PDF and bitmaps

Tooth spacing
Specifies the center to center tooth spacing, as measured along the gear's pitch
diameter.
Type
This selects what type of gear teeth to draw. The gear's teeth can be spur, pinw
heel, or protractor.
Involute
This specifies involute spur gears. Involute spur gears are the most commonly us
ed type of gear. Any two gears that have the same tooth spacing (or pitch) and t
he same contact angle (also known as pressure angle) will mesh and run smoothly.
Pin
For some applications, it is desirable that one gear be comprised of just a ring
of pins. Such gears are also known as "lantern" gears. The pins are typically h
eld together by two discs on either side, so that the whole structure could be s
aid to look like a "lantern". Such a gear may or may not have a shaft passing th
rough the middle of the pins.
The primary advantage of this type of gear is that it's possible to make gears w
ith as few as three teeth that will still run smoothly.
For pinwheel gearing, the gear on the right will always be the pinwheel and the
gear on the left will always be cycloid shaped to mate with the pinwheel.
Protractor
Sometimes it's useful to be able to create a template that divides a circle into
a specific number of intervals. For example, to divide a circle into 23 equal p
arts with a protractor would be tedious and error prone. Using this program you
can print a template that divides the circle as specified.
Shaft spacing
This field always displays the calculated shaft spacing value. The shaft spacing
is the sum of the pitch radii of both gears. Pitch radius is calculated from th
e pitch circumference. Pitch circumference is equal to the number of teeth times
the tooth spacing.

You can also enter a new value in this field and the gear's tooth spacing will a
utomatically be recalculated to produce the desired center to center distance fo
r the two gears.
Contact angle
This field specifies the contact angle, also known as pressure angle, for involu
te spur gears. Larger pressure angles produce gears that have more triangular lo
oking teeth. Larger pressure angles work better for gears with a small number of
teeth, but the overall result is lower efficiency due to higher friction in the
gear set.
This field is only applicable for involute spur teeth and is hidden if other typ
es of gear teeth are selected.
Pin diameter
This field specifies the size of the pins for pinwheel gearing. This field is on
ly applicable to pinwheel gearing and is hidden if other types of gear teeth are
selected.
Gear ratio
I have had nuerous requests to make the gear program display ghe gear ratio. The
reason the program does not explicitly display the gear ratio is that the gear
ratio is whatever you enter. For example, if you have a tooth count of 7 and 12,
the gear ratio is 7:12. That is to say, the 7-tooth gear will turn 12 times for
every 7 turns of the 12-tooth gear. Similarly, a 10-tooth with a 30-tooth gear
will have a gear ratio of 30:10, which can also be epxressed as 3:1.
Gear properties
This section allows you to specify the parameters specific to each gear.
Show
Selects whether the gear is visible. Note that for pinweel gears, the properties
of the pinwheel affect the shape of the mating gear, so even if the right gear
is hidden, its properties still affect the gear on the left.
Spur
Selects a regular spur gear. That is, a round gear with teeth on the outside.
Ring
Selects a ring gear. A ring gear is a gear with teeth on the inside. Ring mode c
an only be selected if the other gear is a spur gear. Ring gears are useful when
making planetary gear sets
Rack
Selects a "rack" type gear. A rack is essentially a gear that has been unwrapped
. Rack and pinion mode is only currently available for involute tooth types.
Teeth
Specifies the number of gear teeth.
Odd shaped gears generated by setting the right side gear addendum to zero.
Addendum
Specifies the addendum of the teeth. The addendum is how much the gear tooth pro
trudes outside its pitch diameter. It is specified relative to the tooth spacing
. That is, a setting of 0.25 means that a tooth's addendum will be one quarter o
f the spacing, or about half of its width.
The gear's dedendum (that is, how deep a cut beyond the pitch circle between tee
th) is taken from the mating gear's addendum. So to set the dedendum of a gear,

just set the corresponding addendum of the mating gear.

Note that cycloid gears don't use the addendum parameters.
Spokes & more tab
Diametric pitch
Some people prefer to use diametric pitch, as opposed to tooth spacing (also kno
wn as circumferential pitch). Diametric pitch is equal to the gear's tooth count
divided by the pitch diameter, so this number varies inversely with tooth size.
Please note that version 2 and earlier of the gear generator calculated this as
diameter per tooth (inverse of what it should be). You can enter a value in the
diametric pitch, and the circumferential pitch on the main tab will automatical
ly be updated.
Slop
The amount
re printed
dth of the
n also add

of total slop, play, or tolerance. With slop set to zero, the gears a
so that they fit exactly, with no tolerance for slop. Usually, the wi
cut on the bandsaw or scroll saw will provide enough slop, but you ca
slop by setting this parameter.

Pitch diameter
The pitch diameter is the diametric pitch times the number of teeth. The pitch d
iameter is useful for working out gear spacing. The ideal center to center dista
nce of a pair of gears is equal to the sum of the pitch diameters, divided by tw
o. Note that the shaft spacing in the "Gear properties" tab already shows the ce
nter to center distance as "shaft spacing".
Overall diameter
This displays the overall diameter of the gear, from tip to tip.
Spokes
Specifies the number of spokes. Only spur gears above a certain number of teeth
are large enough to have spokes.
Shaft hole diameter
Specifies the shaft hole to draw. For pinwheel (lantern) gears, this specifies t
he size of the shaft in the middle of the pins. The gear teeth of the mating gea
r will be kept short enough so as not to interfere with the central shaft. Speci
fy zero to omit the center shaft or shaft hole.
Chain & Sprocket mode
The gear template generator version 2.0 includes a "chain and sprocket" mode. Th
is mode is intended to assist in generating sprocket shapes for wooden block cha
ins and roller chains.
Chain & sprocket mode is turned on by selecting the "Chain & Sprocket" tab on th
e bottom left of the main window.
Block chain
Roller chain
The gear template generator can produce both block chain sprockets, and roller c
hain sprockets.
Nearly all modern metal drive chains, such as those used on bicycles, are of the
"roller chain" variety. Roller chains have a cylindrical roller on every pin jo
int, with two sets of links on either side to join them together.
Block chains are an older, obsolete style of drive chain. Block chains are much

simpler to make, and lend themselves well to wood. In a block chain, the sprocke
t engages bocks in the middle of the chain. Each block has two holes, to which t
he links on either side attach. An example use of a wooden block chain can be se
en in this tank thread vehicle
If the blocks of a block chain are not rounded on the corners, then the corners
tend to scrape the sprocket where the chain engages and disengages the sprocket.
The gear template generator will generate sprocket shapes that make allowances f
or this "undercut" next to the teeth for this, but the sprockets are still somew
hat ugly and inefficient.
A much better solution is to put a bit of a round or chamfer on the edges of the
chain blocks. The sprocket at left is very similar to the previous sprocket, bu
t with blocks that have chamfered corners. Note that the teeth have much less un
dercut.
For clarity, I changed the links to be very thin, but the links do not actually
engage the sprocket, so only the link's length, not its actual shape contributes
to the sprocket shape.
The gear generator can generate shapes for workable sprockets down to three teet
h. However, these sprockets are inefficient and will run very rough. If you use
the "Animate" function in the gear template generator, you can see that the chai
n has quite a bit of side-to-side motion.
The shape of the teeth also doesn't engage the chain very well, as the teeth nee
d to be very sloped to allow the chain to engage and disengage the sprocket.
Sprockets with larger number of teeth will run much more smoothly.

To better see how the chain meshes, parts of the chain and sprocket can be hidde
n. The image at left, for example, has the chain links hidden. You can also hide
the chain entirely. Hiding the chain is useful when making a printout of the sp
rocket template shape to use when cutting the sprocket out of plywood.
The image at left also has the "Show
epresent the pitch diameter, and the
he tooth undercut radii. If you have
ling out the undercut circles, which
the sprocket with a bandsaw
Specifying the chain dimensions

pitch diameter" turned on. The blue lines r

lines crossing it indicate the centers of t
the right size drill, you can start by dril
will make it easier to cut out the rest of

The shape of the sprocket teeth is generated based on the shape of the chain blo
cks, and the length of the chain links.
The shape of the chain blocks and links is specified in terms of length and widt
h. Please note that the specified length is the length between the two holes. Th
e program automatically adds some length to the link to allow for material aroun
d the holes.
An additional parameter, "Chamfer" determines how much to remove from each corne
r of the blocks and links. If "Round chamfers" is selected, the chamfer is repla
ced by a round with a radius equal to the chamfer measure.
Display parameters
This part of the panel selects which aspects of a gear to display.

Show pitch diameter

When selected, a circle is drawn indicating the gear's pitch diameter.
Show line of contact
For involute teeth, this shows the contact angle (pressure angle) and base radii
of the two gears. If you think of the base radii as being two spools, a point a
long a string unwound from the right gear's base radius and wound onto the left
gear's base radius would exactly follow the path along which both gears touch.
Show center
Show a crosshair in the center of each gear.
Draw thicker lines
Doubles the thickness of lines used to draw the gear, so that the lines snow up
better on printouts..
Grid
Draw a grid. The grid is useful for getting a sense of scale, for checking that
a printout was scaled correctly, and to help align multiple pages together when
pasting together multi-page printouts.
Grid diagonals
Draw diagonal lines on the grid. Diagonal lines are very useful to help align th
e sheets of a multi-page printout when gluing the pieces of paper together. The
diagonals grids work so well, I later wrote BigPrint to allow other types of ima
ges to be pasted together this way.
Animate
Slowly turn the gears. This allows you to examine how the gears mesh. Note that
spur gears with less than 10 teeth and low contact angles will often cause inter
ference. For gears with very few teeth, try pinwheel gears.
Wobbly
I implemented "wobbly mode" for the evaluation version of the program. The eval
version can do everything the full version can do, but all output is distorted.
The distorted gears would not work in real life.
I found the distorted "wobbly mode" fun to watch, so I have added this "feature"
as an option to the full version as well, just for fun.
Show rotated
This field causes the gears to be displayed rotated. The angle is specified as o
ne hundredths of a tooth. Specifying 25, for example, will cause the gears to be
rotated by one quarter tooth interval.
This feature is useful if you want to check that spur gears mesh without interfe
rence. It's especially useful if you use the up/down buttons, and zoom in on the
meshing point by reducing the value of the "screen view width" field.
Screen view width
This field indicates how wide an area the screen represents. This value defaults
to 20 cm, or about the width of the printable region on a normal piece of paper
.
Note that this value is in whatever units you chose. If you change the units to
"inches" then the visible region would change to 20 inches, along with all other
dimensions. The display would not change, but when you print it, it will now be

much larger as it's now sized in inches.

Saving
The parameters for a gear can be saved in a file for later reloading. The parame
ters are simply stored in a text file. If a file called "default.gear" exists in
the same directory as the program, it will be loaded automatically when the pro
gram starts.
Units
Units can be selected to be inches, centimeters or millimeters. Note that the di
splayed gear's size does not change if the units are changed. A gear that is 10
cm across, when you change the units to inches, will now be 10 inches across. Th
e screen width would also change from 20 cm to 20 inches. However, on printing o
r exporting, the gears will be scaled accordingly. Note, however, that on import
ing DXF, the units are not specified inside the file. Typically, one must indica
te to the importing program what units are represented in the file.
Printing
The gear template generator is able to print gears that span many pages. If a ge
ar does not fit onto a single page, then the gear is split across multiple pages
to be printed and then glued together.
Grid lines, especially when combined with diagonal grid lines, are very useful t
o help precisely align the pages when gluing them together.
It's advisable to do a print preview before printing your gears. The dimensions
you have specified might result in gears that span a surprisingly large number o
f pages.
Printing parameters
Printer scale calibration
You may find that your printer prints just slightly larger or smaller than it sh
ould, especially if your printer is a laser printer. If you find that 10 grid li
nes of a one centimeter grid are actually 10.1 cm horizontally, you can compensa
te by setting the width calibration to 99%. If you switch to "landscape" orienta
tion, the "width" is actually the length. The labels adjust to reflect this.
Horizontal / vertical / overlap
If you print gears that span multiple pages, the gears are printed with no overl
ap by default. You may prefer to have a slight amount of overlap from page to pa
ge to give you more confidence in aligning the pages. You can either enter the o
verlap, or you can enter the spacing of the pages. Note that the spacing and siz
e of the pages always total up to the printable area on a page.
You may also find that its quite easy to align the pages even without overlap wh
en grid diagonals are enabled.
Print overlap area
You can select whether to print in the overlapped area. This option is only enab
led if an actual overlap is selected using the horizontal/vertical/overlap field
s.
Center gears
Normally, the gears are in the top left of the page, or group of pages. If you c
heck this, the gears will be centered on the page, or group of pages.
Print parameters
If checked, the actual gear parameters will be printed on the top left of the pa
ge.

Exporting
When exporting to a file, everything that is drawn on the screen is exported. Th
is included both gears, as well as any center and grid lines you may have turned
on. It's recommended that you turn off everything but one gear and its center c
rosshair before exporting. Otherwise, it can be difficult to separate the gears
from the grid in whatever program you are importing into.
No printer pagination will be applied to export.
3D gear drawn from gear outline
in Google SketchUp
DXF (with poylylines)
Most CAD programs can import DXF files. The gear template generator's DXF export
is relatively simplistic and only two dimensional, but it will get the shapes i
nto your CAD program.
The DXF export does not include units. Programs that import DXF typically allow
you to specify which units the DXF file actually uses. For example, if you used
inches to design your gear, but the importing program assumes the units are mill
imeters, the imported gear will be much smaller than you expect.
Please note that DXF export with polylines is less than perfect, and that AutoCa
d will not successfully import this. Unfortunately, I have no means of debugging
this. For use with AutoCad, use the basic DXF export.
DXF (basic DXF)
DXF is a very difficult to figure out format, and the DXF exported by the gear t
emplate generator may not be compatible with all programs. If the "with polyline
s" export does not work, try exporting as basic DXF. Basic DXF exports line segm
ents only. Unfortunately, this means some programs will not recognize the outlin
e as a joined object.
SketchUp
One of the most popular CAD programs among woodworkers is the free Google Sketch
Up. However, the free version of SketchUp does not handle DXF import. It does, h
owever, import data in "Collada" format. Because so many people use the free ver
sion of SketchUp, I implemented export to this format so that you can still impo
rt gears into the free SketchUp. As CAD programs go, SketchUp is relatively easy
. But be warned. All CAD programs have a steep learning curve.
When you import a gear into SketchUp, it will be imported as nested objects. Kee
p opening the objects until you have opened the gear outline. To turn the outlin
e into a surface that can be extruded, draw a rectangle around the whole outline
, then delete the outline of the rectangle. If your gear has spoke and center ho
les, select these with a double click, copy them, delete them, then paste them i
n place. After that, you will be able to delete the surface inside the spoke hol
es. I don't think SketchUp works as well as they say it should in this particula
r regard, but the above procedure has worked for me.
HPGL
HPGL stands for "Hewlett Packard Graphics Language". It is the format used by th
e old HP plotters. Nobody uses plotters anymore, but the format is fairly straig
htforward and various pieces of software still know how to import and export gra
phics in this format. I tested HPGL exporting against this HP plotter emulator.
CSV (for spreadsheet)
CSV (Comma Separated Values) is the simplest form of export, consisting of just
two columns of numbers, plus some annotation. This format can be loaded into spr
eadsheets such as Excel. You can display the gears as a graph in Excel by select
ing the two columns of numbers and generating an X-Y scatter graph from the data
.
Displaying gears in a spreadsheet is not particularly useful, but it's a good st

arting point if you wish to manipulate the X-Y points in some way for your own p
urposes.
Image (bitmap)
Exports the image as a bitmap (BMP, Jpeg, or PNG). A window will pop up allowing
you to specify how many pixels per size unit (pixels per inch, per centimeter o
r per millimeter), and whether antialiasing (line smoothing) is turned on.
PDF
The PDF export is intended for importing into laser cutters and such. The "page
size" used is whatever is needed to print the gear. PDF export does not split th
e output across multiple pages.
If you need to create a PDF for printing across multiple pages on another printe
r, the best way to proceed is to print to a file. To print to a file, go to "con
figure printer" under print setup, and select "Microsoft XPS document..." as the
printer. Then print. Windows will prompt you to specify a file to print to. The
n upload the XPS file to http://www.xps2pdf.org/ to convert it to a PDF file. No
te that this trick works with any program that can print to a printer. No need t
o install special software on your computer to create PDF files. There are also
"printer drivers" available on the internet that allow you to print directly to
a PDF file on your computer, but printing to XPS and then converting doesn't req
uire any extra software installation.