Quote Originally Posted by m_c View Post
I think you'd get away with a standard tooth profile, tilted so it matches the correct cone angle.

I'd have to dig out the gear design/machining book I've got buried somewhere to confirm that though.
Trouble is, tooth needs to scale with distance along - tooth width and gap aren't constant. There are some standard ways of getting close using a dividing head and taking three cuts per tooth space but I'm not sure how you would fully automate that.