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Michael aka. "MechEngineerMike" published a very detailed tutorial on how to design and 3d print gears. It's a must-read if you want to print any kind of a gear used in a mechanical movement.Here is a video of his gear light switch cover:
Full tutorial can be found at:
http://www.instructables.com/id/A-Practical-Guide-to-FDM-3D-Printing-Gears/
Here is his collection of customizable gears on Thingiverse:
http://www.thingiverse.com/MechEngineerMike/collections/gears-customizable