How to cut gears on scroll saw

Gear cutting can be a difficult task without the right tools and knowledge. That’s where we come in – with this guide, you’ll be able to cut gears like a pro in no time!

Scroll saws are versatile tools that can be used for a variety of tasks, including gear cutting. In this guide, we’ll show you how to use your scroll saw to create perfect gears every time.

With the right know-how, anyone can cut gears using a scroll saw. By following our simple guide, you’ll be able to create beautiful gears that will function perfectly in your projects.

How to cut gears on scroll saw:

Here are some steps to follow for gear cutting on a scroll saw:

1. Choose the right blade:

There are a variety of blades available for scroll saws, and each one is suited for a different task. When cutting gears, you’ll need a blade with particularly sharp teeth. We recommend using a fine-tooth blade for the best results.

2. Measure and mark your gear:

Before you start cutting, you’ll need to measure and mark the shape of your gear on the wood. Use a ruler to measure the diameter of your gear, then use a pencil to mark out the shape.

3. Cut out the gear:

Once you’ve marked out the shape of your gear, it’s time to start cutting! Use a slow speed and gentle pressure when cutting your gear – this will help ensure that the blade doesn’t miss its mark.

4. Sand and finish your gear:

Once you’ve cut out your gear, it’s time to sand and finish it. Use fine-grit sandpaper to smooth out any rough edges, then apply a coat of wood finish to protect the surface.

And that’s all there is to it! With these simple steps, you’ll be able to cut beautiful gears using your scroll saw. Have fun experimenting with different shapes and sizes.

Safety Tips:

Here are some safety tips to keep in mind when cutting gears on a scroll saw:

1. Wear safety goggles to protect your eyes from flying debris.

2. Make sure the blade is sharp and in good condition. A dull blade can cause the gear teeth to break off, which could cause injuries.

3. Keep your hands and fingers clear of the blade at all times.

4. Don’t try to force the gear over the blade. If it’s too big, cut it into smaller pieces that will fit onto the blade.

5. Don’t overload the scroll saw with too many gears at once. Start with a few and work your way up if needed.

Common mistakes:

Here are some common mistakes people make when cutting gears on scroll saw:

1. Cutting the gear too small

This will result in a weak gear that might not work properly.

2. Not using a backer board

This can cause the gear to become misaligned and will affect its performance.

3. Not using a lubricant

This can cause the gear to heat up and potentially damage the saw blade.

4. Cutting the teeth of the gear too close together

This can also weaken the gear and make it difficult to turn.

5. Not checking the fit of the gear

Make sure that the gear fits properly in its housing before cutting it out.”


is there any special blade for cutting gears?

There is no special blade for cutting gears. However, you will need to use a fine-tooth blade in order to get the most accurate results.

Can I cut gears out of different materials?

Yes, you can cut gears out of different materials. However, you will need to use a blade that is compatible with that material. For example, a blade that is designed for cutting wood will not work well with metal.

Can I use my scroll saw to cut other shapes besides gears?

Yes, you can use your scroll saw to cut other shapes besides gears. However, some shapes are more difficult to cut than others. You may need to practice a bit before you can get the desired results.

How do I know if my gear is properly aligned?

One way to test for proper alignment is to turn the gear by hand. If it feels difficult to turn, then it may be out of alignment. You can also try fitting the gear into its housing. If there is a lot of friction, then it is likely out of alignment.

What should I do if my gear is out of alignment?

If your gear is out of alignment, you can try to adjust it manually. However, if it is severely out of alignment, you may need to re-cut the gear.

How do you determine the size of gear you need to cut? 

The size of gear you need to cut will depend on the application. You will need to measure the diameter and thickness of the gear and then use those measurements to calculate the size of the gear you need to cut.

Can I use my scroll saw to cut through multiple gears at once?

It is possible to cut multiple gears at once using a scroll saw. However, you will need to use a blade that is compatible with all of the materials you are using. Additionally, you will need to be careful not to overload the saw.

Can I use my scroll saw to cut gears out of metal?

No, you cannot use a scroll saw to cut gears out of metal. You will need to use a blade that is specifically designed for cutting metal.


We showed you how to cut gears on a scroll saw. It is not difficult, but it does take some practice to get the hang of it. Once you do, you will be able to create gears quickly and easily.

We hope this article has been helpful. If you have any questions, please don’t hesitate to ask them in the comments section.