Barrel Key Cutting: What It Is, Who Does It, and How It Works

When you think of a key, you probably picture a flat, toothed piece of metal. But not all keys are like that. A barrel key, a cylindrical key with pins along its surface, commonly used in padlocks, vending machines, and older automotive systems. Also known as cylinder key, it’s not cut with a standard key machine—you need specialized tools and training to replicate it. Barrel key cutting isn’t something you do at home with a DIY kit. It’s a trade skill, practiced by licensed locksmiths, trained professionals who install, repair, and duplicate keys for locks of all types, especially those working in commercial or automotive settings.

Unlike regular keys, barrel keys don’t have ridges on the edge. Instead, they have tiny grooves or notches along the barrel’s surface that line up with pins inside the lock. Cutting one means matching those exact patterns—too deep, and the key won’t turn; too shallow, and it won’t engage the pins at all. This is why key duplication, the process of making an exact copy of an existing key using a matching blank and precision machine for barrel keys requires calibrated equipment and experience. You can’t just walk into any hardware store and get one copied. Most places don’t even carry the right blanks or machines. That’s why you’ll often find barrel key cutting services offered by local locksmiths, not big box retailers.

Barrel keys are common in older locks, public transit systems, vending machines, and some industrial equipment. If you’ve ever tried to copy a key for a locker, a bike lock, or an old car ignition and got told it couldn’t be done, chances are you were dealing with a barrel key. The skill to cut them is in demand because these keys are still in use—just not widely understood. And if you’re learning a trade, knowing how to cut barrel keys opens doors to repair jobs, mobile locksmithing, and even working with property management companies that handle hundreds of these locks.

There’s no degree required. No college. Just hands-on practice with a key duplicator designed for cylindrical blanks, a good understanding of lock mechanics, and patience. Many locksmiths start by learning standard key cutting first, then move to barrel keys because they’re trickier and pay more. Some even specialize in them. If you’ve ever wondered how someone can open a lock without the key or make a copy of a weird-looking key, that’s the kind of work barrel key cutting is part of.

Below, you’ll find real guides and breakdowns from people who’ve done this work—whether it’s how to tell if a key is a barrel type, what tools to use, or how much it costs to get one cut. No theory. No fluff. Just what works on the job.