ABSTRACT – Spur gears are employed for transferring both motion and power from driver shaft to driven shaft. The performance of Spur gears largely depends upon its design and construction. Thus there is a need for inspecting spur gear before deployment. During the inspection, a spur gear will be checked for pitch circle, diametral pitch, center distance, outside diameter, etc. Many techniques have been proposed by researchers for the measurement of gear elements. Many of these techniques are contact-based and are fit for sampling inspection. These techniques are not amenable to automation. Sampling inspection techniques are not fool-proof. With the advent of 3D printing and Industry 4.0, there is a thrust is toward 100% inspection. This has necessitated the need for designing and developing new inspection techniques for measuring spur gear elements in real-time. In the present research, an attempt has been made to design and develop a new non-contact and online, technique for inspecting spur gears in real-time. The measurements made by using the proposed method are validated by standard methods and are in good agreement.