Key Cutting and Duplication: Milling and Stamping Guide
Key Types and Materials
Key manufacturing uses brass for residential, nickel-silver for premium and steel for high-security. Cut depth tolerance ±0.03mm for smooth operation. Standard pin tumbler keys have 5-7 cuts at precise depths matching the lock cylinder.
Keyway profiles vary by lock brand. Restricted key systems have patented keyway shapes that cannot be duplicated without authorization.
| Key Type | Material | Process | Tolerance |
|---|---|---|---|
| Residential | Brass | Milling | ±0.05mm |
| High Security | Nickel-silver | Milling | ±0.03mm |
| Padlock | Brass/steel | Stamping | ±0.07mm |
| Automotive | Steel | Milling | ±0.03mm |
Cutting Methods
CNC milling: 30-60s per key, ±0.03mm precision. Stamping: 2-5s, ±0.07mm, limited to simple profiles. Laser cutting: 10-20s, ±0.02mm, for restricted blanks. Tracer copying: 60-120s, ±0.10mm, from worn originals.
Depth and spacing calibration performed daily. Code cutting from numerical key codes for new duplicates without an original.
| Method | Speed | Precision | Best For |
|---|---|---|---|
| CNC Milling | 30-60s | ±0.03mm | All types |
| Stamping | 2-5s | ±0.07mm | Simple profiles |
| Laser | 10-20s | ±0.02mm | Restricted |
| Tracer | 60-120s | ±0.10mm | Worn originals |
Quality Control
Go/NoGo gauge for insertion and rotation in lock cylinder. Optical comparator for cut depth measurement. Cycle test with lock cylinder for smooth operation. Surface inspection for burrs on cut edges.
Material verification for steel keys. Keyway profile measurement for restricted systems. Dimensional check of bow width and length.
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