A key maker uses a key-cutting machine that replicates existing keys onto blank keys. This process essentially traces the original key and simultaneously cuts a new key to match.
The Key-Cutting Process Explained
The key-cutting process relies on a relatively simple but precise mechanism. Here's a breakdown:
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Key Selection: The key maker first selects a blank key that is compatible with the lock the key is intended for. This means choosing a blank that has the correct shape, size, and material (typically brass or steel).
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Placement in the Machine: The original key (the master key) is placed in one clamp of the key-cutting machine, and the blank key is placed in a corresponding clamp. These clamps are designed to hold the keys securely and in alignment.
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Tracing and Cutting: The machine has two main components:
- Tracer: A guide that follows the contours and grooves of the original key.
- Cutter: A rotating cutting wheel that grinds away material from the blank key.
As the tracer moves along the original key, following its unique pattern of ridges and valleys (the "teeth"), the cutter simultaneously duplicates that pattern onto the blank key. The tracer and cutter are linked, so their movements are synchronized.
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Grinding and Shaping: The cutter, which is often made of hardened steel, precisely grinds away the metal of the blank key to match the shape of the original. The key maker may make multiple passes to ensure accuracy.
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Deburring and Finishing: After the key is cut, the key maker will often deburr the key, removing any sharp edges or metal shavings. This ensures the key operates smoothly in the lock and is comfortable to handle. They might use a wire brush or file for this.
Tools Used by a Key Maker
While the key-cutting machine is the primary tool, key makers may also use:
- Key blanks: A wide assortment of uncut keys to match various locks.
- Deburring tools: Files or brushes to smooth the edges of newly cut keys.
- Key gauges: Tools to measure key dimensions and ensure accuracy.
- Lock picks (if they also perform locksmithing services): Tools to open locks without the original key.
Different Types of Key Cutting Machines
While the basic principle remains the same, key-cutting machines can vary in complexity and automation. Some are manual, requiring the key maker to guide the tracer, while others are automated, using computer-controlled milling to precisely replicate keys.
In summary, a key maker uses a key-cutting machine to meticulously copy the pattern of an existing key onto a blank, ensuring that the new key will operate the corresponding lock.
