Physical Security: Key Forging Project (OpenSesame)

[khofo]

Project Name:  OpenSesame
Creator: khofo
Status:  Design and Development

Lately I was very interested in physical security, it's a fascinating field to say the least.
So my first project will consist of a device to forge any key pretty quickly.

How it works:

I am using 123D design (a basic free 3D design software), to create a shell for the molding device.
The molding device is pretty simple to connected shells with a hinge, you put the key inside and press.
When it dries the melt metal is poured inside to make a key.
I will post the schemes for the mold once i am done, I still have the hinges to design (I am no expert).

Help Requested:

I am no chemist, and I do not have much knowledge about chemistry, that's why I am asking for help selecting some of the materials, actually the core materials.
 
1. The molding material: 


The molding device is an empty shell, and it should be filled with a material to take the shape of the key and preserve it,     criteria for it:

   - Withstand temperatures higher than 90  Degrees Celsius without deforming, burning etc..
   - Do not shrink or deform while drying.
   - To be consistent and dense enough to be contained in the mold without spilling, even upside down.
 
  Examples of not compatible materials:
                                                                      - Clay: Clay tends to shrink a bit while drying, (correct me if wrong)
                                                                      - Dry Soap, Playdoy, etc: Cannot withstand high temperatures
 
  2. Choice of the metal:


I need some sort of metal (alloy or not), criteria:
   
   - Melts around 90 Degrees Celsius, (melt by a lighter)
   - Strong enough  to bear the pressure exerted by the cylinder and the hand without bending
   - Not friable, crumbly (broken keys in a lock are serious pain in the ass)


Why I do not just pick it or bump it ?

Well simply my keys are not 'pickable' or 'bumpable'
Here is a picture showing the kind of keys I am trying to forge, they are pretty common here, also no blanks and no machines to copy them easily





It's just an experiment I do not expect it to work, and I am open to any corrections and/or suggestions

[forallintensivepurposes]

Hello Khofo,

Very interesting project you have here. Perhaps the project here could give you some ideas for a molding compound:

http://www.instructables.com/id/Copy-a-Key-by-Casting/

If you get the chance, read the comments on the page. I found them pretty informative.

I hope this helps you,

[khofo]

Hello Khofo,

Very interesting project you have here. Perhaps the project here could give you some ideas for a molding compound:

http://www.instructables.com/id/Copy-a-Key-by-Casting/

If you get the chance, read the comments on the page. I found them pretty informative.

I hope this helps you,

I reviewed the above link, I'll take this molding compound into consideration, and thank you so much for sharing, also I did check the comments and indeed a graph indicating proper ventilation ports was extremely useful indeed

[HTH]

Those are dimple locks/keys and they ARE pickable. That being said, molding a key in the way you describe is as well.

[proxx]

Those are dimple locks/keys and they ARE pickable. That being said, molding a key in the way you describe is as well.

Which requires serious skill , but yes.
I know these could be sensitive for bumping, seen simliar things.

[khofo]

Those are dimple locks/keys and they ARE pickable. That being said, molding a key in the way you describe is as well.

You are right and thank you for the name berween, dimple locks can be picked, but in entreprise environment (aka my target), there is cameras, so picking a lock is not the most discreet way to go in, and since I could have already access to thre keys for some seconds, the molding technique seems appropriate.

[0x5f]

This is a case for an impressioning attack...

From "Keys to the Kingdom" by Deviant Ollam:

"The use of thin pieces of metal foil in conjunction with specially-prepared keys can sometimes achieve the same effect as conventional impressioning methods. By applying tension to a lock cylinder, and thus causing pins to bind, it is possible to wiggle a key and cause these binding pins to rub. ...

...The technician also has no need to shave metal from the key by filing with hand tools. The use of a malleable medium, such as foil, will cause the key to deform at the point where it rubs against a binding pin. Repeated wiggling and oscillating of the key can result in small depressions in the foil or other soft medium, thus allowing the lock to be opened rapidly… sometimes in seconds...

...In particular, locks that operate using dimple keys are especially suited to this tactic..."

It works...

[dotszilla]

check this video out, they use some type of metal called gallium.. maybe thatll work..

https://www.youtube.com/watch?v=VP_4qKQ-BM0

also i heard of people using zync or like melting coins to make the key mold but im not sure its strong enough but might be worth the try.. let me know if you accomplish your project..

[khofo]

check this video out, they use some type of metal called gallium.. maybe thatll work..

https://www.youtube.com/watch?v=VP_4qKQ-BM0

also i heard of people using zync or like melting coins to make the key mold but im not sure its strong enough but might be worth the try.. let me know if you accomplish your project..

Thank you very much dotszilla for this video,
gallium may be appropriate but I think that zinc could work out better since it doesn't melt in your hand!
and for the molding process itself, I am trying to create a mobile version, where u should have access to the key for few seconds, rather than 6 hours.
Anws your reply was indeed helpful, thanks

[dotszilla]

Thank you very much dotszilla for this video,
gallium may be appropriate but I think that zinc could work out better since it doesn't melt in your hand!
and for the molding process itself, I am trying to create a mobile version, where u should have access to the key for few seconds, rather than 6 hours.
Anws your reply was indeed helpful, thanks

take a look at this link : http://www.instructables.com/id/Copy-a-Key-by-Casting/?ALLSTEPS

although his outcome didnt look too good as far as the key went, but you can maybe get an idea from it...