Gear Generator is a tool for creating involute spur gears and download them in SVG format. In addition it let you compose full gear layouts with connetct...
The SVG files load into Adobe illustrator as vectors and I can run them into my laser cutter.
To ratify the precise gear size, if you can design you gear on it and get it cut (1/4" acrylic?) and working on your laminator I can take the file to the CNC people and see what it costs to do a batch.