How to Make a Key Mold

Making a key mold for basic or simple key duplication can be a practical skill for various situations, such as creating a backup key or when replacements aren't readily available. Here's a step-by-step guide on how to make a key mold:

Materials and Tools Needed:

1. Key you want to duplicate (original key)

2. Silicone sealant (RTV silicone or similar)

3. Release agent (cooking spray or petroleum jelly)

4. Disposable container or mold tray

5. Wooden sticks or toothpicks

6. Tape

7. Gloves

Instructions:

1. Prepare the Key:

- Start with a clean original key. Remove any debris or dirt using a soft cloth or brush.

2. Apply Release Agent:

- Spray or rub the release agent onto the key, especially in intricate areas, to prevent the silicone from sticking to the key.

3. Create the Mold:

- Place the original key in the disposable container or mold tray, ensuring it lies flat.

- Pour the silicone sealant over the key, making sure to cover the entire surface. If necessary, use a stick to gently nudge the silicone around the key.

4. Remove Bubbles:

- Gently tap or vibrate the container to release any air bubbles trapped inside the silicone.

5. Add Supporting Elements (Optional):

- If the key has gaps or voids within the design, you may need additional support to prevent the silicone mold from collapsing during hardening. You can insert pieces of wood or toothpicks into these gaps to provide internal support.

6. Let it Cure:

- Allow the silicone sealant to cure and solidify completely as per the product instructions. This can take several hours or overnight.

7. Remove the Key:

- Once the silicone mold is fully hardened, carefully peel away the container or mold tray. Gently lift the original key out of the silicone mold.

8. Trim and Clean the Mold:

- Trim any excess silicone around the edges of the mold with a hobby knife or scissors. Clean the mold with water or rubbing alcohol to remove any remaining release agent or residue.

9. Test the Mold:

- To test the mold, press a new, uncut key blank into the silicone impression you've created. Gently press the key blank into all the details and remove it. Check to see if the key blank has picked up the imprint of the original key.

10. Make Duplicate Keys:

- You can use the mold to make duplicate keys by inserting uncut key blanks into the mold and allowing them to fully harden. Make sure the key blank material is compatible with the mold (usually plastic or metal).

11. Store the Mold:

- Store the silicone mold in a cool, dry place, protected from direct sunlight and harsh temperatures, when not in use.

12. Safety Precautions:

- Always use gloves when working with silicone sealant to protect your hands and prevent skin irritation.

Remember, this method is suitable for basic key duplication. For more complex keys with intricate designs, it's recommended to consult a professional locksmith or use specialized key duplication services.