Hi,
I've been working on a special gear design for my 3D print project and was able to draw a very nice involute gear profile using a modified Circular Array script.
The process of designing the gear was hybrid, I only used the function to create the undercut by roll-arraying the center point of a rack tooth circular tip, then drawing a through point spline and offsetting it by the tip radius.
For the tooth I just used standard involute shape made by FxGraph3D script:

_FxGraph3D a*(cos(u)+u*sin(u));a*(sin(u)-u*cos(u));0;0;6.283185307179586;0;0;50;0;1;;;V

, as the array produces involute profile at some arbitrary points along the rack tooth edge, which are hard to trace with a hand-drawn spline.



I've used Gemini Pro model to generate this script (see attachment ZIP). The principle works like this:
Simple straight-line rack rotates around a circle with a offset, such that there's no slip at a given radius. The circular array function has "Radial Step" parameter which does just that when it's a negative value.
The script works only for a rack placed on the bottom of the gear or top (negative radius must be used). This modified script accepts the roll radius/diameter value as input (tooth module * number of teeth = diameter) and calculates corresponding "Radial Offset".

Now I have an issue, because I want to create a non-circular involute gear, and I need to "roll-array" the rack over a curve (arch) with parallel offset to the curve to avoid slip at each step. I believe it would be possible with MoI, the script would essentially be the "Curve Array" with a roll offset option.
I haven't tried to make it using AI yet, and maybe some human ingenuity already made something like it. Anyway just asking.

I might be onto something, did some research and maybe the correct method for creating such meshing gears would be a Curve Envelope script, that would trace a rolling shape of one curve over the other, in my case a straight rack over a curve arch. The script would work on a "tooling curve" first (here the rack curve) and expect it to be selected first, then selecting the roll path curve. It would expect that the initial position of the two is in its initial meshing position.
The roll path curve is essentially a pitch curve for a spur gear.

That would be all that's needed for production of the Envelope curve. The exact points making the envelope are a result of two parameters, position along rack curve and rack roll progress which drives its position and rotation. The Rack motion just assumes a straight rolling over the pitch roll curve, parallel at contact.

I got the idea from this video https://youtu.be/eG-z-791_ak?t=652