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I spoke at some length with Schuyler Towne at openlocksport about the possibility of taking a photo of a key and printing it. Here's a first attempt I made - haven't gotten back to it.

http://www.flickr.com/photos/13723140@N04/5585943473/in/photostreamhttp://www.flickr.com/photos/1...

It didn't work, but I see no reason it shouldn't, in theory. The PLA is plenty strong enough to act as a key at the required thickness. Schuyler suggested following on the work of some university students who've already got an
algorithm worked out, which utilizes a database of key manufacturer's specs to make sure the end product is correct.

In illinois, as of this year, it's illegal to buy, sell, trade, or give lockpicks. I wonder if this design tests the law?