Here is a gear model with an involute built using graphical ("unwind string" method). Cumbersome, but accurate.
Toolbox gear teeth are trash. Geatrax produces passable results but not 100% accurate (based on 2008 sample models). http://esoxrepublic.com/blog/2008/05/28/spline-curvature-and-geartrax/
You can use equation-driven curves to produce involutes. I've done this recently. Works well. This month I expect to replace my other "graphical" gear template with an equation-driven involute model.
Not sure if this would be any help. I still use sometimes old Autocad routines (LSP) for precise drawing of gears. I tried to duplicate what you are trying to do and enclesed is JPG file showing the gears. I have drawn both gears in Solidworks (using drawing generated in AutoCad as sketch) and I could send them to you if you ask.
We want to make some steel gears and plan to wire cut them so toolbox gears are useless. I don't really have much time to create the accurate models and wouldn't really know where to start as I haven't had to do it before.
I found MITCALC which seems to be very powerful but rather complex as well. I did manage to get a dxf out of the software and then copy and pasted from draftsight into solidworks. The problem I am having is that the sketch consists of lots of line segments rather than continuous splines / polylines. I suspect this will cause performance issues with solidworks.
Does anyone know how I can convert into polylines or splines without losing profile accuracy?
Also I would like to persue modeling up a stable equation driven model for future use if anyone can provide some direction it would be appreciated.