ABSTRACT In this study, geometrical equations of elliptical spur gears, which are too difficult to manufacture by traditional methods and which require specific machines equipped with special techniques, are developed using the methods in the literature. Using these equations, a LISP program on AutoLISP is created to model elliptical spur gears on AutoCAD with desired tooth number and modules. Elliptical spur gears are manufactured with 5 different modules by Wire EDM through the above-mentioned package program. The variations in the center distances of elliptical spur gears, the most important parameter for workability of gears, are experimentally determined by a simple test unit designed and manufactured within the context this study. In addition, the surface roughness and hardness of elliptical spur gears are obtained and hydraulic pump and noise analysis results are discussed. The experimental and computer-aided results show that the elliptical spur gears may widely be used in many industrial and mechanical applications in the future.