I need to make some gears/pinions myself. I have access to a high quality 4-axis CNC mill, but not to a lathe. I'd like to cut these gears out of flat stock (facing), rather than round (edgewise) using narrow end mills. Being able to prototype this in plastic sheets is important to me.
I've found a bunch of sites that explain hobbing and that have formulas for pitch etc, but no sites that actually generate the splines for the gear teeth to turn into Gcode.
Before I sit down with Mathematica and derive it from first principles, does anyone know of a good resource for this?