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A method is proposed to manufacture spiral bevel gear by duplex spread blade method based on 4-axis CNC milling machine. Firstly, the geometry parameters and machine-tool settings are comprehensively considered. To meet with the tooth taper, a new way is raised to select reference point. Then machine-tool settings are calculated that only first-order mesh performance is guaranteed in the reference point. Therefore conjugate tooth surface is modified by a surface represented as second-order polynomial to optimize mesh performance, as a result a target tooth surface is established, and according to the sensitivity matrix the machine-tool settings are corrected. Finally, the proposed method is illustrated by a numerical example to reveal it’s effective and feasible.