Free Rack and Pinion Generator - Linear Gear Calculator, Simulator & DXF Export
GearDXF is the internet's most versatile free online rack and pinion generator. Design custom straight linear gear racks and matching involute spur pinions with micron-level mathematical precision. Whether you are building a CNC router gantry, a robotic linear actuator, an automotive steering mockup, or a 3D printed slide mechanism, our tool lets you configure geometry, test linear travel in real-time simulation, and export clean DXF, SVG, and PDF files without ads, watermarks, or paywalls.
Rotary to Linear Motion Kinematics & Formulas
A rack and pinion mechanism operates by converting rotational torque into linear thrust. The linear pitch of the rack is defined as p = π × m (where m is the module), matching the circular pitch of the driving pinion. The linear displacement per revolution of the pinion equals the pitch circumference: L = π × d = π × m × z. For rack and pinion systems where high positioning repeatability and zero slip are vital, involute gearing provides constant pressure angle transfer along the linear pitch line.
Straight Involute Rack Tooth Geometry
Mathematically, a rack represents a spur gear with an infinite radius. Consequently, the involute curve straightens into a flat, planar surface angled at the pressure angle (standard 14.5°, 20°, or 25°). GearDXF automatically constructs straight-sided rack teeth with precise root fillets, addendum clearance, and user-defined backing bar thickness to support heavy mechanical loads without deflection.
Custom Pinion Design: Bores, Keyways & Spokes
The mating pinion can be configured with standard shaft bore diameters for stepper motors (NEMA 17, NEMA 23, NEMA 34) or servo motor drive shafts. Add standardized DIN/ANSI keyways to eliminate slipping under heavy torque, or apply weight-saving circular and rectangular spoke cutouts for high-speed robotic gantry systems.
Backlash Tuning for CNC Gantries & 3D Printing
Laser beam kerf, CNC endmill deflection, and FDM plastic swelling can cause tight gear teeth to bind. GearDXF's integrated backlash compensation lets you thin the teeth symmetrically, giving your physical assembly the exact clearance needed for smooth, low-friction linear sliding motion.
Real-Time Dynamic Linear Simulation
Experience seamless browser-based mechanical simulation. Connect your pinion to the linear rack, set motor RPM, and observe the linear stroke and travel velocity. Verify tooth mesh engagement, backlash clearances, and total physical travel stroke before cutting into expensive metal or acrylic stock.
Production-Ready DXF & SVG Vector Export
Download both the rack and pinion as clean, closed-polyline vector files. Guaranteed compatibility with CAM software including Vectric Aspire, Autodesk Fusion 360, SolidWorks, AutoCAD, LightBurn, LaserCAD, and SheetCAM. Also export 1:1 scale printable PDF patterns for manual machining and scroll saw woodworking.
Frequently Asked Questions (Rack & Pinion)
What is a rack and pinion generator? A dedicated engineering web tool to calculate, simulate, and export straight linear gear racks and meshing pinions for digital fabrication.
How do I calculate travel per revolution? Travel distance = π × Module × Number of Pinion Teeth.
What pressure angle is recommended? 20 degrees is the universal standard for strength and smooth engagement in CNC and robotics.
Can I export for CNC routing? Yes, exported DXF files contain clean closed loops ready for CNC profile milling.
- CNC Gantry Drives: Design long linear drive racks with high stiffness and minimal backlash.
- Robotics & Automation: Create compact linear actuators, grippers, and pick-and-place slides.
- 3D Printing: Print custom linear mechanisms with tuned tolerances directly from SVG/DXF extrusions.
- Woodworking & Clockmaking: Build wooden automata, lifting jacks, and mechanical clock racks.
100% free client-side tool. Your designs remain private and secure on your device. No registration or credit card required.