How to Solve the Problem of Fragile Car Key Shells and Loose Key Blades – OEM Manufacturer Insights

As an automotive key OEM manufacturer, one of the most frequent concerns we hear from our clients and distributors is:

“The key shell breaks easily after a fall” or “The metal blade becomes loose over time.”
These are valid concerns, especially when quality and durability are essential for customer satisfaction and brand reputation.

In this article, we will explain the root causes of these issues and share our OEM-level solutions to help our partners deliver higher-quality, longer-lasting car keys.

Common Issues: What Customers Are Experiencing

Key shell cracks after impact – A small drop can result in visible cracks or broken corners.

Key blade becomes wobbly or detaches – The internal metal-to-plastic connection wears out.

Buttons fall out or become sticky – Caused by weak rubber molding or poor assembly.

Root Causes Behind Fragile Key Shells and Loose Blades

Low-grade plastic materials (e.g., recycled ABS) used to reduce costs.

Inconsistent injection molding leading to weak shell structure.

Improper assembly during production causing stress points inside the shell.

Insecure fixing of the metal key blade (e.g., loose pins or poor internal locking mechanisms).

OEM-Grade Solutions We Provide

As a manufacturer, we take a proactive engineering approach to address these challenges at the design and production level:

1. Use of Reinforced Materials

We use virgin-grade ABS+PC blends that provide:

Higher impact resistance

Better heat tolerance

Improved overall toughness

This helps ensure the key shell won't easily crack even when dropped from standard operating heights.

2. Upgraded Internal Reinforcements

Our key shells feature internal rib structures that distribute shock evenly and prevent stress concentration.
This minimizes the risk of breakage at typical weak points like corners or screw holes.

3. Precision Molding & Quality Control

We invest in high-precision injection molds and enforce 100% visual and structural inspection on all housings.
This ensures:

Uniform wall thickness

No air pockets or molding defects

Smooth button integration

4. Metal Blade Locking Technology

We’ve engineered metal key blade fixation systems that include:

Double-locking pins

Steel reinforcement rings

Tight-tolerance blade sockets

These measures prevent the blade from loosening or detaching, even after thousands of folds and uses.

5. Drop-Test Certified

All our keys go through real-world drop tests (up to 1.5m) to simulate daily wear and tear.
Only shells that pass the impact resistance standards are approved for bulk production.

How It Benefits Your Business

Lower return rates from end users

Stronger reputation for product reliability

Improved customer satisfaction with tactile feel and long-term durability

Competitive edge over lower-quality suppliers

Work With a Trusted OEM Key Supplier

As a leading OEM in the automotive key industry, we focus on quality, innovation, and support. Whether you are a distributor, wholesaler, or workshop owner, our products are built to perform under real-world conditions.

Interested in stronger, smarter, and more reliable car key solutions?
Contact us today for product catalogs, samples, or OEM customization options.

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