Key Cutting Explained: How It Works, Types of Keys, and What You Should Know

 

Introduction – Why Key Cutting Matters

Every day, millions of South Africans use keys—whether it’s to unlock their homes, offices, or cars. We often don’t give them much thought until something goes wrong: a key is lost, broken, or simply not working. That’s when key cutting becomes essential.

Despite being one of the most common locksmith services, many people misunderstand how it works. Some think it takes forever, others assume all keys can be copied at a hardware store, and some believe “Do Not Duplicate” stamps make keys impossible to copy. The truth is, key cutting is both a science and an art. Done correctly, it ensures smooth access, prevents damage to locks, and provides peace of mind.

In this guide, we’ll break down everything you need to know about key cutting: how it works, different types of keys, costs in South Africa, and why choosing the right locksmith matters.

What Is Key Cutting?

At its core, key cutting is the process of creating a duplicate or replacement key. It can be as simple as making a spare for your front door or as complex as cutting and programming a high-tech car fob.

The process involves using an original key (or a code from the lock) as a guide to cut a blank key into the exact shape required. Once the blank is cut and smoothed, it should fit the lock perfectly, turning with ease just like the original.

Key cutting isn’t just about duplication—it also includes creating new keys from scratch when no original is available. This requires skill, specialized machines, and sometimes access to manufacturer codes.

 

A Brief History of Key Cutting

Keys and locks have been around for thousands of years:

·         Ancient Egypt & Babylon – The earliest locks were wooden with large, simple keys.

·         Ancient Rome – Metal keys made from iron and bronze emerged. These were bulky but more durable.

·         Middle Ages – The invention of warded locks introduced more complexity, requiring precisely cut keys. Skeleton keys were born during this time.

·         Industrial Revolution – In 1917, one of the first modern key duplicating machines was invented in the United States. This allowed locksmiths to quickly and accurately cut flat metal keys.

·         Today – We now have laser key cutting, computerized code cutting, and even digital key duplication. Yet, the principles of precision and craftsmanship remain the same.

 

How Key Cutting Works (Step by Step)

Although machines make the process look easy, professional key cutting involves careful steps:

1.       Identify the key type – Is it a house key, car key, safe key, or restricted key?

2.       Choose the correct blank – A blank is the uncut key that will be shaped. Using the wrong blank will result in a useless key.

3.       Secure both keys in the machine – The original goes in one vice, the blank in another.

4.       Cutting – The machine traces the original key’s grooves and shapes while cutting the blank to match.

5.       Deburring – Any sharp edges are smoothed with a wire brush. A poorly deburred key can damage locks or cut fingers.

6.       Testing – The new key is tested in the lock to confirm it works smoothly.

 

A skilled locksmith ensures accuracy at every step. A badly cut key won’t just be inconvenient—it can damage your lock over time.

 

Types of Keys and Cutting Methods

Flat Keys

Common in padlocks, cabinets, and older locks. They’re thin and rectangular, cut using simple duplication methods.

Tubular or Barrel Keys

Cylindrical in shape, often used in vending machines or older car locks. Cutting requires specialized tubular machines.

Warded (Skeleton) Keys

One of the oldest designs, with notches that fit around wards inside the lock. Rare today but still found in antique locks.

Dimple Keys

Look like flat keys but with small round depressions (dimples). These require precision cutting and are harder to duplicate.

Double-Sided Keys

Common in modern homes and offices. Both sides have cuts, allowing smoother operation.

Car Keys

These include traditional metal keys, transponder chip keys (post-1998 in South Africa), and fobs with remote functions. Cutting often requires programming.

High-Security & Specialty Keys

Keys like Medeco, Abloy, or BiLock use patented blanks and restricted systems. Cutting is only legal through authorized locksmiths.

Costs and Turnaround Times

In South Africa, key cutting is generally affordable, but prices vary by type:

·         Basic house keys – R30 to R50.

·         Mortice or Chubb keys – R60 to R100.

·         Safe or high-security keys – R150 and up.

·         Car keys (without chips) – R300 to R500.

·         Car keys with chips or fobs – R1000 to R2,500+, depending on make and model.

 

Turnaround times also differ:

·         Standard house keys: under 5 minutes.

·         Car keys: 15–60 minutes, sometimes longer if programming is required.

·         Restricted or special keys: may take several days if ordered through the manufacturer.

 

Car Key Cutting (Traditional, Chip, Fob, VIN)

Car key cutting deserves special attention:

·         Traditional metal keys – Simple to duplicate if you still have the original.

Transponder (chip) keys – Introduced in SA in the late 1990s. These need programming to match the car’s immobilizer system.

Remote fobs – Combine physical keys with remote locking. These require both cutting and electronic programming.

Keys cut from VIN numbers – If you’ve lost all keys, a locksmith or dealership can use the Vehicle Identification Number to retrieve the key code and cut a replacement. Proof of ownership is required.

 

Restricted Keys vs. Do Not Duplicate Keys

You’ve probably seen a key stamped “Do Not Duplicate.” In South Africa, this is usually just a discouragement—not a legal restriction. Some hardware stores may refuse to copy them, but others won’t.

 

Restricted keys, however, are different. They’re protected by patent and law. Only authorized locksmiths with the right blanks can cut them, and only with proper paperwork and ID. These are common in offices, apartment complexes, and government facilities.

   

Common Problems and How to Avoid Them

·         Poorly cut keys – cause sticking or lock damage.

·         Wrong blank used – makes the key useless.

·         Wear and tear – duplicating worn keys can lead to inaccurate copies.

·         DIY kiosks – convenient, but often inaccurate compared to a locksmith.

 

Tip: Always carry a relatively new key for duplication, not one that’s worn down.

 

How to Identify Your Key

·         Check the key head for numbers or letters.

·         Look for codes stamped on the lock itself.

·         Recognize the brand (e.g., Yale, Kwikset, Union, Abloy).

·         If unsure, a locksmith can identify it for you.

 

Why You Should Always Have a Spare Key

Having a spare is a simple way to save money and stress:

• Prevents lockouts.
• Saves on emergency locksmith call-out fees.
• Convenient for households (1 per occupant + trusted neighbour/family member).
• Businesses can control access by issuing limited, tracked spares.

 

Choosing a Trusted Locksmith vs. DIY/Hardware Stores

While hardware stores and kiosks are convenient, they can’t match a locksmith’s precision. Here’s why you should choose a professional:

• Accuracy – Locksmiths ensure perfect alignment and deburring.
• Security – Professionals respect restricted key protocols.
• Expertise – Can handle complex keys, chips, and fobs.
• Guarantees – Reputable locksmiths stand by their work.

In South Africa, look for locksmiths who are registered, reviewed, and experienced. Mobile locksmith vans are especially useful for car key emergencies.

 

The Future of Key Cutting

The industry continues to evolve:

•  Laser cutting – Already common for high-security and car keys.
• CNC machines – Allow for ultra-precise duplicates.
•  3D printing – Being tested for rapid prototyping of keys.
• Smart locks & biometrics – Growing in popularity, but traditional keys will remain for decades to come.

 

FAQs

How long does it take to cut a key?

Basic keys take 2–5 minutes. Car keys with chips or fobs may take up to an hour.

Can all keys be copied?

No. Restricted keys require authorization, and some car keys need special equipment.

What’s the difference between “Do Not Duplicate” and restricted keys?

“Do Not Duplicate” is advisory. Restricted keys are legally protected and can only be cut by authorized locksmiths.

Can I get a car key cut without the original?

Yes, using the VIN number and proof of ownership.

Is key cutting safe?

Yes, when done by a professional locksmith. Poorly cut keys can damage locks, so always use a trusted expert.

 

Conclusion

Key cutting is more than just a quick service at the mall—it’s a skilled craft that blends precision, security, and convenience. From making a spare house key to programming a modern car fob, the process requires expertise to ensure accuracy and safety.

If you’re near Phumlani Mall or Lion Pride Shopping Centre, South Africa, and need fast, reliable, and affordable key cutting, Unilock Key Cutting Services is here to help. We also provide shoe repair, dry cleaning, and shoe care products—all in one convenient location.

📍 Visit us at Phumlani Mall or Lion Pride Shopping Centre

📞 WhatsApp us on 082 568 2612

Don’t wait until you’re locked out—get your spare key cut today!