Export Gears as a “DXF” file-type.
We will add then export Gears.
Note:
Please refer to earlier tutorials if these instructions to add the Gear-Pair do not provide enough details.
In MechDesigner: Prepare and Add Gear-Pair
STEP 1: Add Line and Dimension in Base-Part.
1.Edit the Base-Part
2.Add Line ( Geometry toolbar, left)
3.Add Dimension to the Line (Geometry toolbar, left)
You do not need other dimensions and constraints to control the position of the Line. However, it is good design practice to fully locate of the Line.
4.Exit Part-Editor
You will see the Line in the Mechanism-Editor as a Green Line
STEP 2: Add two Parts.
1.Add Part × 2 (Press the Insert key as a Shortcut key for Add Part).
2.Add Pin-Joint × 2 : Do Add Pin-Joints to join one Part to the start-Point of the Line, and the other Part to the end-Point of the Line(Step 1)
Now you have two Parts that rotate, that you have joined to a Line in a stationary Part.
STEP 3: Add a Motion-Dimension FB to one of the Parts, and Linear-Motion FB
One of the rotating-Parts is a Rocker
1.Decide which Part whose motion you want to drive the motion of the other Part with the Gear-Pair.
2.Click Kinematic FB toolbar > Add Motion-Dimension FB
See Command-Manager:
A)Pin-Joint
B)Line in the Base-Part
C)CAD-Line along center of the Part
The two Lines must radiate (be rays) from the Pin-Joint.
3.Click 
in Command Manager
4.Add a Linear-Motion FB. You can also add other FBs to control the rotation of the Rocker.
5.Edit Motion-Dimension FB and set Base-Value to 0 (usually) - again good practice to know the starting angle of the Driving Gear.
STEP 4: Add Gear-Pair.
1.Click Machine elements toolbar > Add Gear-Pair
See: Command-Manager
Click:
1.Line 1 - the CAD-Line along Part defined by Motion-Dimension
2.Line 2 -the CAD-Line along center of Blue Part - the free-Part.
3.Line 3 - the Green Line in the middle that has a Pin-Joint at each end.
The Part Editor opens automatically.
4.Dimension 1 : the dimension for the length of Line 3.
Now Gears should show and all Parts are defined and Green.
STEP 5: Edit Gear Pair
Edit the Gear-Pair to open the Gear-Pair dialog
Edit the Number of teeth and module
Also, if you want to make really accurate gear representation in SOLIDWORKS, increase # Points along Profile
The DXF file size will increase rapidly as you increase the number of points.
Try default value of '6' and increase if needed.
STEP 6: Run menu > Home key to put gears at home
ALT+H as shortcut.
STEP 7: Solids toolbar > Add Polyline (MD-Solids menu > Add Polyline)
The Solids toolbar is above graphics-area.
You do not need to add a Profile to the Polyline to export DXF to SOLIDWORKS.
Export the Gears
You can choose to export the two gears together, or one gear at a time.
Gears together.
1.Click the Assembly-Tree
2.Click the Mechanism element ONE TIME in the Assembly Tree
The Mechanism element must be in the Selection-Window.
2.Click File menu > Save as
“Save as type” is automatically set to the DXF file-type.
3.Edit the file-name and click Save
One Gear.
1.Click the Part-Outline with the Gear you want to export.
Note: If the Gear is attached to the Base-Part, then you must select the Mechanism element - see Gears together, above
The Part element must be in the Selection-Window.
2.Click File menu > Save as
Make sure the DXF file-type is active
3.Edit the file-name and then click Save
Do 1 - 3 again to export the other Gear.
Open the Gears In SOLIDWORKS
In SolidWorks:
1.File menu > New Part:
In the new SolidWorks Part document:
2.Select the Plane or surface onto which you want to add the DXF of the Gear(s)
3.Insert menu > DXF/DWG...
4.Browse to the DXF file of the Gear(s) you have saved from MechDesigner.
5.Select “Import to part as: 2D sketch” in the DXF/DWG Import dialog
6.Select the “Next” button
In the DXF/DWG Import - Document Settings dialog - make sure Units of imported data drop-down are equal to those of the MechDesigner model millimeters (top left of DXF/DWG dialog)
7.Click Finish
Do 2 to 6 for each Gear
You should be able to extrude the gears from the imported sketch.