I'm testing laser-cut gears for a project I'm working on, and thought some other makers might be able to benefit from the layout I made. This is a series of 13 sets of 4 gears each. Each set contains a gear with 11, 19, 23, and 31 teeth.
I drew them with the Inkscape involute gear renderer using increasing circular pitch from 1px to 13px. For the 11-tooth gear, this corresponds to pitch radii varying from roughly 0.5mm (I don't expect this to work well) to roughly 6.4mm.
The smallest three sets use a 3/4mm hole for an axle; for those playing along at home, this corresponds to a US size 6/0 (UK size 22) knitting needle. The rest of the sets use a 2.5mm hole, corresponding to a US #1 knitting needle. This size doesn't seem to have a UK equivalent (oops!) but I'll be updating the design soon to fix that.
I've started by ordering test gears in 3mm acrylic; I don't have any results yet, but when I do I'll post them over here: http://support.ponoko.com/entries/20522201
Anyone else who orders test gears is encouraged to post their results in the same thread. I'll also post photos as I get test results from new materials.