What's your budget?
#2 I would grind a flycutter and cut the teeth individually with the gear blank on a dividing head.
#3 You can buy milling cutters but they are not cheap and you need a different cutter for each DP (Diametrical Pitch) or Module number that you use and each cutter only covers a small range of size (ie No. of teeth). Look for Involute gear cutters on Google there are lots of sources in the UK. Second hand stuff is cheaper look at www.homeand workshop.co.uk or a company called Tracy Tools Ltd. (no website) +44(0)1803 833134