Free Sheet Metal Gear Generator | 2D Flat Patterns for Sheet Fabrication

Design flat sheet metal gears for laser cutters, plasma tables, and CNC punch presses. GearDXF produces clean 2D profiles that nest tightly on sheet metal blanks to minimize scrap, with customizable tooth clearances and hub mounting holes for press-fit collars and standoffs.

Key Features

• 2D flat pattern DXF export compatible with TruTops, BySoft, and sheet metal CAM
• Nesting-friendly profiles with minimal spacing for maximum material yield
• Configurable drive keyways and multi-hole bolt circles for shaft collars
• Backlash settings to accommodate sheet metal thickness and piercing tolerances
• Lightweight internal cutouts to reduce rotational inertia and sheet weight
• 100% free tool with instant in-browser generation

Frequently Asked Questions

Can sheet metal gears be stacked to make wider gears?

Yes! A common cost-effective engineering technique is laminating multiple identical laser-cut sheet metal gears together with alignment dowel pins to form a wide, heavy-duty gear.

How thick should sheet metal be for functional gears?

Gears are typically cut from 1.5mm (16 ga) up to 6mm (1/4") plate depending on torque loads. Thicker plate provides more contact surface area and reduces tooth flank stress.

Does GearDXF support lead-in and lead-out points for plasma cutting?

CAM software generates pierce lead-ins automatically. GearDXF ensures all gear outer and bore contours are clean closed loops so your CAM software places pierce points correctly.