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Key duplication refers to the process of creating a key based on an existing key. Key cutting is the primary method of key duplication: a flat key is fitted into a vise in a machine, with a blank attached to a parallel vise, and the original key is moved along a guide, while the blank is moved against a blade, which cuts it. After cutting, the new key is deburred: scrubbed with a wire brush, either built into the machine, or in a bench grinder, to remove burrs which, were they not removed, would be dangerously sharp and, further, foul locks.
Different key cutting machines are more or less automated, using different milling or grinding equipment, and follow the design of early 20th century key duplicators.
Key duplication is available in many retail hardware stores and as a service of the specialized locksmith, though the correct key blank may not be available. More recently, online services for duplicating keys have become available.
In the UK, the majority of the mobile locksmiths will have a dual key cutting machine on their van. The key duplication machine will be able to cut both cylinder and mortise keys, as these are the most popular types of keys in circulation. However, very few will carry a laser key cutting machine, which is sometimes needed to cut high security keys.
Certain keys are designed to be difficult to copy, for key control, such as Medeco; while others are simply stamped "Do Not Duplicate" to advise that key control is requested, but in the US, this disclaimer has no legal weight.
Rather than using a pattern grinder to remove metal, keys may also be duplicated with a punch machine (the Curtis key clipper [1] is a recognised example). The key to be duplicated is measured for the depth of each notch with a gauge and then placed into a device with a numeric slider. The slider is adjusted to match the corresponding measured depth and a lever is depressed, which cuts the entire notch at once. As the lever is raised the key automatically advances to the next indexed position and the slider is adjusted appropriately to the next measured depth. This cycle is continued until the key is complete.
Duplicating keys by this process is more labor intense and requires somewhat better trained personnel. However, keys made in this fashion have clean margins and the depth of the notches are not subject to wear induced changes encountered when heavily worn keys are duplicated using a pattern grinder. Keys may also be made in this fashion without an original as long as the depth of each notch and the type of key blank are known. This is particularly useful for institutions with a great number of locks for which they do not want to maintain a wide variety of archived copies. Code books or on-line resources may be used to program the key clipper/punch settings from the code stamped on the lock, listed in the owner's manual, or available from the vehicle's VIN. [2]
A machine permitting rapid duplication of flat metal keys, which contributed to the proliferation of their use during the 20th century, may have been first invented in the United States in 1917 (image to the left):
The key to be duplicated is placed in one vise and the blank key to be cut in a corresponding vise under the cutting disk. The vise carriage is then into such position by means of a lateral-feed clutch that the shoulders of both the pattern and blank keys just touch the guide disk and cutter respectively. The lateral-feed clutch on the top of the machine is then thrown, and the vertical feed rod released into action and power applied through the combination hand-crank power wheel on the right of the machine, until the cutter has passed over the entire length at the blank. A duplicate of the pattern key is obtained in about one minute.
— "Man And His Machines", The World's Work XXXIII:6 April 1917
In recent years, dual key cutting machines have come on to the market, enabling cutting of both mortice and cylinder keys on one machine. These machines are primarily manufactured in the Far East and save a key cutter a significant amount of money compared with using two separate dedicated machines.
A "do not duplicate" key (or DND key, for short) is one that has been stamped "do not duplicate", "duplication prohibited" or similar by a locksmith or manufacturer as a passive deterrent to discourage a retail key cutting service from duplicating a key without authorization or without contacting the locksmith or manufacturer who originally cut the key. More importantly, this is a key control system for the owner of the key, such as a maintenance person or security guard, to identify keys that should not be freely distributed or used without authorization. Though it is intended to prevent unauthorized key duplication, copying DND keys remains a common security problem.
There is no direct legal sanction in the US for someone who copies a key that is stamped do not duplicate (unless it is an owned key), but there are patent restrictions on some key designs (see "restricted keys"). The Associated Locksmiths of America, ALOA, calls DND keys "not effective security", and "deceptive because it provides a false sense of security." 18 U.S.C. § 1704 deals with United States Post Office keys, and 18 U.S.C. § 1386 deals with United States Department of Defense keys.
A restricted key is a type of key that is designed to limit access to a specific area or object. These keys are typically used in high-security environments, such as government facilities, military bases, and certain businesses that require strict access control.
Restricted keys are unique in that they are only able to be duplicated by authorized individuals or locksmiths who have the proper identification and authorization to do so. This helps to ensure that the key cannot be copied or used by unauthorized individuals.
Some common examples of restricted key systems include master key systems, where a single key can open multiple locks within a building, and key control systems which allow for precise tracking of key usage and access control. Overall, restricted keys are an important tool for maintaining security and controlling access to sensitive areas.
A restricted keyblank has a keyway for which a manufacturer has set up a restricted level of sales and distribution. Restricted keys are often protected by patent, which prohibits other manufacturers from making unauthorized productions of the key blank. In many cases, customers must provide proof of ID before a locksmith will cut additional keys using restricted blanks. Some companies, such as Medeco High Security Locks, have keyways that are restricted to having keys cut in the factory only. This is done to ensure the highest amount of security. These days, many restricted keys have special in-laid features, such as magnets, different types of metal, or even small computer chips to prevent duplication.
Another way to restrict keys is trademarking the profile of the key. For example, the profile of the key can read the name of the manufacturer. The advantage of a trademark is that the legal protection for a trademark can be longer than the legal protection for a patent. However, usually not all features of the profile are necessary to create a working key. By removing certain unnecessary features, a non restricted profile can be derived, allowing the production and distribution of non restricted key blanks.
Lock picking is the practice of unlocking a lock by manipulating the components of the lock device without the original key.
A warded lock is a type of lock that uses a set of obstructions, or wards, to prevent the lock from opening unless the correct key is inserted. The correct key has notches or slots corresponding to the obstructions in the lock, allowing it to rotate freely inside the lock.
In machining, a shaper is a type of machine tool that uses linear relative motion between the workpiece and a single-point cutting tool to machine a linear toolpath. Its cut is analogous to that of a lathe, except that it is (archetypally) linear instead of helical.
A lock is a mechanical or electronic fastening device that is released by a physical object, by supplying secret information, by a combination thereof, or it may only be able to be opened from one side, such as a door chain.
A lever tumbler lock is a type of lock that uses a set of levers to prevent the bolt from moving in the lock. In the simplest form of these, lifting the tumbler above a certain height will allow the bolt to slide past.
A grinding machine, often shortened to grinder, is any of various power tools or machine tools used for grinding. It is a type of material removal using an abrasive wheel as the cutting tool. Each grain of abrasive on the wheel's surface cuts a small chip from the workpiece via shear deformation.
Padlocks are portable locks usually with a shackle that may be passed through an opening to prevent use, theft, vandalism or harm.
A Tool and Cutter Grinder is used to sharpen milling cutters and tool bits along with a host of other cutting tools.
A key blank is a key that has not been cut to a specific bitting. The blank has a specific cross-sectional profile to match the keyway in a corresponding lock cylinder. Key blanks can be stamped with a manufacturer name, end-user logo or with a phrase, the most commonly seen being 'Do not duplicate'. Blanks are typically stocked by locksmiths for duplicating keys. The profile of the key bow, or the large, flat end, is often characteristic of an individual manufacturer.
Bitting is the depth of key cuts on a cylinder key for a pin tumbler lock, often expressed as a number. Bitting also refers to the combination of key cuts on a bit key for a warded lock or lever tumbler lock.
A car key or an automobile key is a key used to open and/or start an automobile. Modern key designs are usually symmetrical, and some use grooves on both sides, rather than a cut edge, to actuate the lock. It has multiple uses for the automobile with which it was sold. A car key can open the doors, as well as start the ignition, open the glove compartment and also open the trunk (boot) of the car. Some cars come with an additional key known as a valet key that starts the ignition and opens the driver's side door, but prevents the valet from gaining access to valuables that are located in the trunk or the glove box. Some valet keys, particularly those to high-performance vehicles, go so far as to restrict the engine's power output to prevent joyriding. Recently, features such as coded immobilizers have been implemented in newer vehicles. More sophisticated systems make ignition dependent on electronic devices, rather than the mechanical keyswitch. A number of these systems, such as KeeLoq and Megamos Crypto have been demonstrated to be weak and vulnerable to cryptanalytic attacks.
Medeco, a subsidiary of the Swedish Assa Abloy Group, is a lock manufacturer located in Roanoke County, Virginia, United States.
A key code is a series of alphanumeric characters used by locksmiths to create a key. There are two kinds of key codes: blind codes and bitting codes.
A wafer tumbler lock is a type of lock that uses a set of flat wafers to prevent the lock from opening unless the correct key is inserted. This type of lock is similar to the pin tumbler lock and works on a similar principle. However, unlike the pin tumbler lock, where each pin consists of two or more pieces, each wafer in the lock is a single piece. The wafer tumbler lock is often incorrectly referred to as a disc tumbler lock, which uses an entirely different mechanism.
Schlage is an American lock manufacturer founded in 1920 by Walter Schlage. Schlage was headquartered in San Francisco from its inception until it relocated to Colorado Springs, Colorado, in 1997. Schlage also produces high-security key and cylinder lines Primus, Everest, and Everest Primus XP. Schlage is one of the most popular brands of consumer and commercial locks in the United States.
An interchangeable core or IC is an adaptable locking key cylinder, which can be rapidly exchanged in the field via the use of specialized "control keys".
In mechanical engineering, a key is a machine element used to connect a rotating machine element to a shaft. The key prevents relative rotation between the two parts and may enable torque transmission. For a key to function, the shaft and rotating machine element must have a keyway and a keyseat, which is a slot and pocket in which the key fits. The whole system is called a keyed joint. A keyed joint may allow relative axial movement between the parts.
In master locksmithing, key relevance is the measurable difference between an original key and a copy made of that key, either from a wax impression or directly from the original, and how similar the two keys are in size and shape. It can also refer to the measurable difference between a key and the size required to fit and operate the keyway of its paired lock.
Key control refers to various methods for making sure that certain keys are only used by authorized people. This is especially important for master key systems with many users. A system of key control includes strategies for keeping track of which keys are carried by which people, as well as strategies to prevent people from giving away copies of the keys to unauthorized users. The former may be as simple as assigning someone the job of keeping an up-to-date list on paper. A more complex system may require signatures and/or a monetary deposit.
This is a glossary of locksmithing terms.