Worm face gears are often good alternative for worm gears. The gear can be molded or forged. The pinion is an involute screw - easy to manufacture. Worm face gears are used on rotary actuators popular in automotive industry,

1. Worm Face Gear
3d CAD modeling in SolidWorks using
special Excel VBA macro from
Dr. Stepan V. Lunin. 2016.

2. Generate Worm Face gear tooth surface files using special Excel file
from Spiral Bevel Corporation.
Run VBA Macros to generate each gear tooth flank.

3. Open both flanks in SolidWorks

4. Build the root surface any way you like. This example shows smooth
surface tangent to each flank.

5. Sketch the gear blank.

6. Make the gear blank from sketch.

7. Connect both flanks and the root surfaces into one surface.

8. Cut the blank with the surface.

9. Circular pattern the slot for number of teeth

10. Use the final 3d CAD model for manufacturing and inspection.