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Could you 3D print a spare emergency key?

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1.2K views 16 replies 6 participants last post by  corollacoaster  
#1 ·
I have a third fob for the car but it's missing the emergency key insert. But I'm wondering if you could duplicate one of the existing emergency keys on a 3D printer and is there material strong enough to do the job of a key or too much risk of it breaking off in the door lock if you ever had to use it? Thinking I would carry it in my wallet so always on hand and then wouldn't need to spend the extra $60 for one for the fob (price from dealer with cutting). Not played around with 3D printing so not sure of the capabilities or materials available.
 
#2 ·
If you are thinking about getting a friend to 3D print a key, i doubt that would work.First, you would need some way of copying the key into a digital file to be used by the printer. The printer would need to be accurate enough for the job, and the choice of filament would need to be easily melted while strong enough to act as a key reliably.
A local locksmith might be able to cut an emergency key at a reasonable price, but it would likely not be able to be stored in the fob.
 
#3 ·
Getting the digital file is no problem, our tech club has a high end 3D scanner where they've scanned antique auto parts to make 3D molds. I just didn't know if there is some super filament that would take the torque of using the key. Don't think there is but figured probably some tech heads on here that might know. Carbon fiber is strong enough but too flexible. The locksmith I went to can only cut the Toyota blank so wouldn't fit in my wallet but I may just settle for putting it in the spare fob.
 
#6 ·
These keys cannot be punched like days of old, they are laser cut. The emergency key does not have any kind of chip (it will not start the car), it is purely to enter the car if your fob battery has gone dead. The dealer wants $30 for the blank and $50 to cut it. There is no flat key blank, they all come with the plastic head although I could probably dremel that off but for $80, I would just carry it in the fob as intended. I didn't think there was any material strong enough in 3D printing just thought it would be so simple to scan the image and duplicate it but breaking a plastic key off in the door lock would cost more than the $80 for a locksmith to remove.
 
#7 ·
The photo below is the Key for our 2025 Camry. Very similar to our 2018 Kia. This is not Laser Cut. You can actually see the machine marks from the end mill used to cut the channel.

Could this be done with 3D printing - Possibly. Hard to say for sure without the tolerances. IMHO, not worth the effort to try and troubleshoot.


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