<p>To improve transmission performance and reduce the impact of meshing in and out, a design method based on a sinusoidal profile cutter for the tooth surface crowning of spiral bevel and hypoid gears is proposed. Initially, a mathematical model for the sinusoidal blade profile and gear cutting process is established, and the influences of blade profile parameters on tooth surface mismatch are obtained using numerical analysis methods. The optimization model of the tool profile parameters is proposed by presetting the tooth contact characteristics with the objective function of minimizing the angular acceleration of the peak relative motion. Finally, the transmission performance simulations and rolling test results of two pairs of gears, before and after blade profile optimization, demonstrate that spectral analysis comparison significantly reduces maximum acceleration on the driving and coast sides, and decreases transmission noise by 1.8 dB, evidently enhancing the transmission performance of the gear pair.</p>