All Activities

Design and create a gear

Design and create a gear
Green highlight

Design and create a cardboard gear, cut teeth, assemble axle, test meshing with another gear and observe how gear size changes speed and direction.

Orange shooting star
Background blob
Challenge Image
Skill Badge
Table of contents

Step-by-step guide to design and create a cardboard gear

What you need
Cardboard sheet, pencil, ruler, compass or round cup, piece of string, scissors or craft knife, brad fasteners or tape, drinking straw or wooden skewer, tape, adult supervision required

Step 1

Gather all materials on a clear table so you can work without losing anything.

Step 2

Place a cup or use a compass to draw two different-sized circles on the cardboard for two gears.

Step 3

Cut out the two cardboard circles carefully with scissors or a craft knife.

Step 4

Find and mark the center of each circle by drawing two straight lines across and marking their crossing point.

Step 5

Pick how many teeth each gear will have and write that number on each circle.

Step 6

Wrap the piece of string once around a circle and mark where the string meets to measure its circumference.

Step 7

Measure the marked string length with the ruler and divide that number by the tooth count to get one tooth spacing.

Step 8

Fold or mark the string into equal segments using the tooth spacing measurement so each fold is one tooth wide.

Step 9

Lay the folded string around the circle and make small pencil marks at each fold to mark every tooth position.

Step 10

Cut small triangular teeth at each pencil mark around the edge of each circle.

Step 11

Make a hole at each circle’s center slightly wider than your straw or skewer and push the straw or skewer through to make an axle; secure with tape or a brad.

Step 12

Put the two gears on their axles with their teeth touching and turn one gear to watch the other move and notice how direction and speed change.

Step 13

Try different-sized gear pairs and count how many turns the small gear makes while the big gear makes one turn to see the speed change, then share your finished creation on DIY.org

Help!?

What can we use if we don't have cardboard, a cup, or a straw/skewer?

Use a cereal box or corrugated packaging instead of cardboard, trace any round lid or jar if you don't have a cup or compass to draw circles, and substitute a pencil or wooden dowel for the straw or skewer axle.

My gears wobble or won't mesh properly—what should I check or fix?

Make sure the center hole is only slightly wider than the straw/skewer so the axle isn't loose, confirm teeth were evenly spaced using the folded string marks before cutting, and if needed tighten the axle with tape or replace tape with a brad to reduce wobble.

How can I change the activity for younger or older kids?

For preschoolers have an adult pre-cut the circles and triangular teeth and let them mark and decorate, for elementary kids let them measure the string, fold for tooth spacing and cut with supervision, and for older kids let them use a craft knife, experiment with different tooth counts, and record gear turns.

How can we extend or personalize our finished gears?

Glue the axles into holes on a cardboard base to build multi-gear trains, paint or label each gear, try more size combinations to observe speed changes and count turns as suggested, and share photos or a video on DIY.org.

Watch videos on how to design and create a cardboard gear

0:00/0:00

Here at SafeTube, we're on a mission to create a safer and more delightful internet. 😊

School Science Projects | Gear Working Model

4 Videos
School Science Projects | Gear Working Model

School Science Projects | Gear Working Model

Kids First Intro to Gears

Kids First Intro to Gears

How to make Cardboard Gears at home || Homemade Gear at Home

How to make Cardboard Gears at home || Homemade Gear at Home

Drawing Gears with a Compass (simplified method)

Drawing Gears with a Compass (simplified method)

Facts about simple machines and gears

🔭 The Antikythera mechanism (around 100 BC) is the oldest known geared device — an ancient analog “computer” for astronomy.

⚙️ Gear ratio = driven gear teeth ÷ driver gear teeth; if the driven gear has twice the teeth it spins at half the speed.

🔁 When two spur gears mesh they rotate in opposite directions — meshing flips the rotation.

📏 Corrugated cardboard is perfect for prototyping gears: it's light, easy to cut, and holds its shape well.

🕰️ Gears come in tiny sizes for watches (under 1 mm) and huge industrial sizes taller than a person.

How to design and create a cardboard gear

To design and create a cardboard gear, start by drawing a circle the size you want. Divide the circumference into equal sections (use a protractor or measure) and mark the teeth positions. Sketch tooth shapes and cut them out carefully. Punch a center hole for the axle, insert a brad or dowel allowing rotation, and mount on a base. To test, mesh with another gear and observe direction and speed; adjust tooth shape or spacing for smoother meshing.

Materials needed for a cardboard gear project

You'll need sturdy cardboard (from boxes or cereal cartons for smaller gears), pencil, compass or round objects to trace circles, ruler and protractor for spacing, scissors and/or craft knife (adult use), cutting mat, hole punch or awl for the axle hole, brad fasteners or wooden dowel for axles, glue or tape, markers or paint for decoration, and an extra gear or gear template to test meshing.

What ages is this cardboard gear activity suitable for?

This activity suits children roughly aged 6–12 with adjustments: ages 6–8 can design, trace and decorate gears with close adult help for cutting and axle assembly; ages 9–12 can measure, cut more precisely, and test gear ratios with supervision. Teenagers can build larger or more accurate gears and explore calculations. Always supervise use of craft knives and small parts to prevent accidents or choking hazards.

Benefits, safety tips, and variations for cardboard gears

Building cardboard gears teaches basic physics, mechanical thinking, fine motor skills, and patience. It's a hands-on way to explore gear ratios, direction change, and torque. Safety tips: use adult help for blades, keep small parts away from young children, and wear eye protection when pushing awls. Variations: try different tooth counts, mix cardboard with plastic lids, stack gears for compound trains, or motorize one gear with a small hobby motor to observe speed changes.

Ready to create?

Make

To create a safe space for kid creators worldwide!

Create

Vibe Coding

Kids GPT

All Tools

Kibu

Learn

Worksheets

Courses

Skills

Resources

SafeTube

Blog

FAQ

Pricing

Account

Log-in

Sign-up

Data Deletion

Company

About

Community Guidelines

Privacy Policy

Terms of Service

2025, URSOR LIMITED. All rights reserved. DIY is in no way affiliated with Minecraft™, Mojang, Microsoft, Roblox™ or YouTube. LEGO® is a trademark of the LEGO® Group which does not sponsor, endorse or authorize this website or event. Made with love in San Francisco.