Precision Flat Broaches, Notch Broaches & Pot Broaching Tools

Custom Keyways manufactures high-quality flat broaches, notch broaches and pot broaching tooling for precision external broaching applications. From standard tooling to fully engineered custom solutions, we provide manufacturers throughout Canada and the United States with reliable broaching systems designed for high production, exceptional accuracy, and long tool life.

Whether you're producing external splines, flats, serrations, or custom profiles, our experienced engineering team can design, manufacture, and support a complete pot broaching solution tailored to your application.

Custom Flat Broach & Notch Broach Manufacturing

Our flat broaches are manufactured to the highest standards using premium high-speed steel and brazed carbide materials to deliver exceptional cutting performance and dimensional accuracy.

Every tool is precision ground and inspected to ensure reliable performance in demanding production environments.

Our capabilities include:

• Standard and custom flat broaches

• Brazed carbide flat broaches

• High-speed steel flat broaches

• Standard and custom notch broaches

• Flat and profile broaches

• Inch and metric designs

• Prototype and production tooling

• Reverse engineering of existing tools

Whether you're replacing worn tooling or developing a new production process, Custom Keyways can manufacture tooling to meet your exact specifications.

Pot Broaching Systems

Pot broaching is one of the most efficient methods for machining external splines, flats, and complex profiles in high-volume production. Custom Keyways designs and manufactures complete pot broaching systems, including precision pot holders and matched sets of flat broaches engineered to work together for maximum accuracy and productivity.

Each system is designed to provide:

• High production rates

• Excellent repeatability

• Superior surface finishes

• Long tool life

• Reduced machining time

• Consistent dimensional accuracy

Our engineering team works closely with customers to determine the ideal broach geometry, cutting sequence, and tooling configuration for every application.

Sharpening & Regrinding

Proper maintenance is essential to maximizing the performance and lifespan of flat broaches. Our precision sharpening and regrinding services restore cutting edges while maintaining the original tool geometry and profile accuracy.

Every tool is carefully inspected before regrinding to evaluate wear, damage, and remaining service life. Our goal is to remove only the material necessary to restore cutting performance, helping extend tool life and reduce overall tooling costs.

Our sharpening services provide:

• Extended tool life

• Improved surface finishes

• Consistent part quality

• Reduced production downtime

• Lower tooling costs

We also offer repair and rework services for damaged tooling whenever practical.

Premium Tool Coatings

To maximize wear resistance and production life, Custom Keyways offers a wide range of premium PVD coatings through our trusted coating partners. We recommend the most suitable coating based on your workpiece material, cutting conditions, and production requirements.

Available coating options include:

TiN (Titanium Nitride)

A proven general-purpose coating that reduces friction, improves wear resistance, and extends tool life in many machining applications.

Alcrona Pro®

Designed for demanding production environments, Alcrona Pro provides exceptional heat resistance and outstanding wear protection for difficult materials and long production runs.

Dyna Blue TiCN

Dyna Blue TiCN offers increased hardness and abrasion resistance while reducing friction during cutting, making it an excellent choice for high-volume manufacturing and abrasive materials.

If your application requires a specialized coating, our team can recommend the best solution to maximize performance and tool life.