Author: rapid_dev

When a leading North American manufacturer serving the aerospace and defense industry began automating more of their CNC operations, one thing kept getting in the way: their workholding. 

Despite running a high-end UMC-1250 with a pallet pool, the shop was struggling with OEM-compatible base plates that simply couldn’t deliver the reliability or precision they needed. Misalignments, worn interfaces, and inconsistent pallet locking were creating delays, rework, and downtime—costing them both time and trust. 

Their team needed more than just compatible tooling. They needed a solution that would remove friction from their workflow—and a partner who understood what was at stake. 

The Breaking Point: A System That Couldn’t Keep Up 

Their EROWA MTS-compatible plates were supposed to streamline operations. Instead, they became the bottleneck. Each mismatch or mechanical issue triggered hours of manual corrections, interrupting the precision flow their industry demands. Even worse, long OEM lead times made it impossible to respond quickly when a replacement was needed. 

When the situation finally became unsustainable, they turned to Rapid Holding Systems. 

Listening First. Then Solving. 

We approached the challenge by doing what we do best: listening. The shop’s goal wasn’t just better tooling—it was to regain control. To achieve smoother automation, consistent results, and setup reliability they could trust. 

That’s where our MTS-Compatible Base Plate came in. 

Our recommendation: the RHS MTS Base Plate – EROWA ER-041600 Compatible, custom-built to their 180 x 360 mm configuration. With a 200 mm center distance between locators and lateral air-control access, it integrates effortlessly into robotic workflows and supports repeatable, high-precision setups. 

We also included optional boreholes for custom machine table configurations. 

From Test to Transformation 

After installing the first RHS base plate, the difference was immediate. 

Setup became faster. Precision improved. Downtime dropped. And their team could finally rely on the system to do its job—without micromanagement or backup plans. 

The real proof? They ordered two more systems, back-to-back. 

RHS had not only solved the problem—they had exceeded expectations. 

Cost Savings and Confidence 

Beyond performance, the switch to RHS brought another major advantage: cost savings. 

By choosing our MTS-compatible base plates, the manufacturer cut their palletization tooling costs by nearly 50%, while gaining better service and technical support. 

Our team worked closely with their engineers to make sure every detail aligned with their goals—not just in theory, but in daily production. 

A Better Way Forward 

This story is not just about a better tool. It’s about building a better process. 

With Rapid Holding Systems as a guide, the manufacturer turned a chaotic, unreliable setup into a streamlined, confident workflow. 

Now, they’re not chasing compatibility—they’re leading with it. 

Ready to take control of your workflow? 

Let’s talk. 

Explore EROWA-Compatible Base Plates 

When it comes to aluminum diecast mold making, most shops know it’s no walk in the park. Unlike plastic injection molds, diecast tooling involves molten aluminum, Dievar steel blocks, and deep, complex cavities that require both precision and durability. These types of jobs can wear down your tooling, consume too much machine time, and lead to unstable setups — especially when dealing with awkward angles or deep ribs. 

At Rapid Holding Systems, we recently worked on a challenging diecast mold project for a Canadian customer — and it was the perfect example of how the right workholding solutions can completely change your workflow. 

The Problem: Deep Cavities + High-Wear Steel 

This project involved machining Dievar steel blocks — a tough material chosen for its durability under extreme conditions like molten aluminum casting. The mold required deep cavities, tight tolerances, and side-mounted setups for boring mill operations. Conventional fixtures simply wouldn’t offer the stability or flexibility needed. 

The question was: 
How can we safely machine complex geometry into hardened steel blocks, without compromising precision or tool life? 

✅ The Solution: RHS Tooling for Deep and Rigid Setups 

Using Rapid Holding Systems tooling, we were able to set up, machine, and EDM burn this diecast mold block efficiently and precisely. 

Tools used in this project: 

1. 🔧 RHS EDM Extensions 
   These extensions allowed us to burn deep cavities that couldn’t be reached by standard tools. Built for Wire EDM and EDM burning operations, they’re rigid, precise, and designed for difficult geometries. 

2. 🧱 RHS U Holders 
   Our U Holders helped secure the graphite during EDM setup and ensured consistent positioning for critical dimensions. 

3. 🛠️ CNC Pull-Down Units 
   Compatible with FCS and Schunk-style systems, these pull-downs allowed us to side-mount the blocks on the boring mill. With M16 threaded screws and precision-ground spigots, the result was a rigid and accurate setup that could handle both vertical and horizontal machining. 

💡 Why It Matters for Other Machinists 

Whether you’re machining plastic molds, aluminum diecast cores, or high-precision steel components, the right workholding system can save hours of setup time and prevent costly errors. 

By integrating modular EDM extensions, precise U holders, and rigid pull-down clamping systems, your shop can: 

• ✅ Eliminate vibration and deflection during deep cavity machining 

• ✅ Speed up changeovers between setups 

• ✅ Improve repeatability and reduce scrap 

• ✅ Handle tougher jobs with more confidence 

Ready to Upgrade Your Diecast or EDM Setup? 

This project is just one example of how Rapid Holding Systems tools are helping moldmakers, machinists, and manufacturers across North America solve real-world challenges on the shop floor. 

If you’re tackling deep cavity EDM burns, complex diecast molds, or want better setups for your CNC boring mill — we’ve got your back. 

📩 Contact us today to find the right solution for your next job: 
👉 [email protected] 
🌐 rapidholdingsystems.com 

For Wire EDM Shops, Setup Isn’t Just a Step—It’s the Foundation 

In Wire EDM, precision isn’t a luxury—it’s survival. Whether you’re cutting aerospace components or delicate medical parts, even the slightest misalignment can wreck tolerances and scrap an entire job. So why are many shops still relying on guesswork when it comes to aligning their chucks and pallet systems? 

The Wire EDM Master Ruler from Rapid Holding Systems offers a smarter way to calibrate your work envelope—accurately, repeatably, and with minimal downtime. 

What It Is (And Why It Matters) 

This isn’t just another ruler—it’s a master reference tool designed for System 3R-compatible setups. Built with a precision-machined indicating face and laser-etched coordinates, the ruler allows machinists to align their chuck and pallet systems to the machine’s wire path with pinpoint accuracy. 

• ✅ Comes in a durable case for protection 

• ✅ Compatible with 70mm 3R-style pallets 

• ✅ Includes an indexed spigot and chuck interface 

• ✅ Etched with X, Y, and Z coordinates for direct offset readings 

If you’re using a 3R-compatible chuck mounted to your EDM rails, this master ruler tells you exactly where your zero-point is—so every fixture, vise, or electrode holder clamped to it aligns perfectly from job to job. 

Why Shops Are Upgrading to Master Rulers 

🔹 You Need Repeatable Accuracy 

Your entire EDM setup depends on knowing where your chuck is. With the Wire EDM Master Ruler, you can quickly thread your wire through the master hole, indicate along the ruler face, and pick up precise offsets without complex macros or manual math. 

🔹 It Speeds Up Your Setup 

The ruler mounts directly onto your chuck and rail system using a fitted spigot. No need to tweak or shim—just lock it in, calibrate once, and go. The quick-spigot interface mimics real production conditions, so what you set up is what you get. 

🔹 It Reduces Scrap and Rework 

By giving you the Z height and XY offsets right from the tool, you avoid part misalignment and tolerance stack-ups. The result? Better first-article accuracy and fewer bad parts on the back end. 

How It Works: Step-by-Step Setup 

1. Mount Your 3R-Compatible Chuck 
   Bolt your chuck directly to your EDM rail system using standard M8 holes. 

2. Insert the Spigot into the Master Ruler 
   Give it a twist—the locking dogs engage and pull the spigot down into the chuck’s seating face. 

3. Lock It In 
   Use the included plastic locking ring to secure the assembly. The ruler is now seated with full XY and Z contact. 

4. Thread Your Wire Through the Master Hole 
   Indicate along the flat face and set your EDM program zero based on the etched measurements. 

5. Record the Offsets 
   With laser-marked dimensions like “X: 9.981 mm, Y: 130 mm, Z: 24.523 mm,” you can now set up your tooling with confidence. 

Who This Is For 

If you’re a Wire EDM machinist, production manager, or maintenance engineer dealing with tight tolerances and setup variability, this is your tool. 

This master ruler is built for: 

• Shops using System 3R-compatible tooling 

• Teams tired of wasting time on manual alignment 

• Anyone chasing tight ±0.005 mm tolerances 

• Facilities aiming to scale production without increasing downtime 

Final Word: The Master Ruler Isn’t Optional—It’s Foundational 

This isn’t a “nice to have.” For shops that run high-precision jobs, a master ruler is essential. The RHS Wire EDM Master Ruler helps you lock in your setup, protect your tolerances, and avoid surprises on the final cut. 

👉 Ready to Stop Guessing? 

Let’s get your shop calibrated the right way. 
📩 Contact Our Technical Team 
🔧 See Product Details & Specs 

Stop wasting time adjusting fixtures. Here’s how System 3R-compatible tools can transform your EDM setup—and your results.

Frustrated With Wire EDM Setups That Just Don’t Work?

If you’re in Wire EDM Machining, you already know the pain: your machine is programmed, everything’s ready—and then you hit a setup issue.

The clamp doesn’t fit. The fixture isn’t aligned. You’re chasing tolerances by feel. And now you’re wasting valuable time and risking scrap.

This is the hidden cost of incompatible or makeshift EDM tooling—delays, part failures, and endless adjustments.

But what if your setup kit made the process fast, predictable, and accurate?

Meet the 3R-242HP-Compatible Wire EDM Setup Kit

At Rapid Holding Systems, we’ve designed a setup solution for real machinists working with System 3R EDM tables. Our 3R-242HP-Compatible Kit is built to help you save time, reduce scrap, and get back to cutting—faster and more accurately.

This isn’t just a collection of parts—it’s a system designed for repeatability, tight tolerances, and setup efficiency.

What’s Inside the WireEDM Clamping Kit?

This setup kit includes everything you need for secure, fast, and accurate fixturing:

• 3R-225 Compatible Reference Stop – helps prevent overtravel and defines machine origin
• 3R-272HP Compatible Leveling Adapter – 3-axis adjustment to dial in precise alignment
• Three SuperVices – versatile clamps for round and square parts (Ø8–90 mm)
• Torque Wrench (7 Nm) – protects your tooling from overtightening
• Allen Keys (3 mm and 5 mm) – included for quick setup on the machine table

All components share the same bolt pattern and dowel configuration, making it easy to switch between parts without realigning from scratch.

Built for the Realities of Your WEDM Shop Floor

While some kits claim to be “universal,” this kit is engineered specifically for System 3R wire EDM machines like Makino, Mitsubishi, Sodick, and AgieCharmilles.

3-point leveling makes it simple to align in X, Y, and Z.

Eccentric dowels let you fine-tune for micron-level adjustments.

All-metal construction ensures repeatability and long-term durability.

Interchangeable vises hold everything from small squares to awkward round parts.

Setup Demonstration: From Table to Tolerance in Minutes

Here’s how it works, step-by-step:

1. Mount the leveling head onto your pre-aligned rail system.
2. Use the eccentric screw to align your fixture side-to-side.
3. Adjust the back and side screws for front-to-back and depth alignment.
4. Install your preferred clamping system—flat vise, lobster claw, or universal.
5. Place your workpiece, torque it with the included wrench, and you’re cutting.

No shimming. No guesswork. No wasted time.

https://youtu.be/bJd2-zrhuy4

Is Your Current Tooling Helping—or Holding You Back?

With tighter tolerances and shorter deadlines, you need tooling that works as hard as you do.

The System 3R-Compatible 3R-242HP Kit gives you a proven path to quicker setups, better results, and lower stress in every production run.

Ready to Upgrade Your Wire EDM Workflow?

Talk to a tooling specialist now

When a customer came to us with a broken EROWA pallet, it didn’t seem like a big deal at first, just a few damaged locator fingers. But those tiny parts were doing a huge job. 

They were part of a fully automated CNC setup. A robot was handling the pallets, loading tools, and keeping everything running around the clock. That is, until the fingers snapped off. 

Suddenly, automation came to a grinding halt. The robot couldn’t recognize the pallet. The CNC machine wouldn’t run. The whole process was stuck, all because of a small mechanical failure. 

They had a decision to make: 

 
Wait weeks (and spend big) on a new EROWA pallet from the OEM, or see if someone could help faster. 

That’s when they called us. 

At Rapid Holding Systems, we’ve seen this before. We know how critical it is to keep precision tooling aligned, especially when you’re relying on robotic workflows. So we got to work fast, not just replacing the broken piece, but improving it. 

We built them a fully EROWA-compatible chuck, custom-fit to match the original specs, and added our own upgrades along the way. High-strength materials. Better durability. And our signature precision calibration features. 

Once we mounted our chuck to the customer’s existing pallet base, we used our EROWA calibration tool to fine-tune the alignment. It wasn’t guesswork—it was exact: 

• We verified the Z datum using the ground feet. 

• We centered everything using both the OD and ID faces. 

• And we tested the system under air pressure to make sure it locked in perfectly. 

No more guessing. No more delays. 

A few days later, the pallet was back in their hands, calibrated, tested, and ready to run. The robot recognized it instantly. The CNC line started moving. And just like that, production was back on track. 

They didn’t just get a replacement. They got peace of mind, and a new go-to team for tooling support. 

We love these kinds of wins. Not because we sold a part, but because we helped solve a real problem. And because we proved that you don’t have to wait weeks or overspend just to get your production line moving again. 

If you’re running an EROWA system and one small failure is threatening to slow everything down, give us a call. 

We’ll build the right fix fast, precise, and built to last. 

Let’s keep your CNC running, not waiting. 

Talk to our team today  

Email : [email protected] 
Phone : +519-999-9723 

Choosing between System 3R and Erowa-compatible tooling isn’t just about brand preference—it’s about ensuring compatibility, maximizing uptime, and eliminating costly setup errors. If you’re unsure which tooling ecosystem fits your EDM or CNC workflow, this breakdown is for you. 

Why Compatibility Matters 

When every micron counts and downtime eats into your margins, tool compatibility is key. Whether you’re machining complex molds, aerospace parts, or high-volume automotive components, your tooling should work with you, not against you. 

Rapid Holding Systems (RHS) eliminates the guesswork with 100% compatible Erowa ITS and System 3R Macro tooling—engineered for performance, priced to fit your budget. 

Tooling System Overview 

System 3R Compatible Workholding Tools 

RHS Macro Systems seamlessly mirror System 3R Macro tooling, offering North American shops a full line of reliable, precision-engineered workholding solutions—at 40–50% of OEM cost. 

These tools are optimized for both EDM and CNC applications, offering fast setup, repeatability, and modularity. Our tools are built to match System 3R standards in every detail—without the premium price. 

EROWA ITS Compatible Tooling 

Built to seamlessly integrate with Erowa ITS systems, RHS delivers a fully compatible lineup tailored for demanding EDM applications. 

Erowa tooling from RHS is known for its stronger palletization profile, making it ideal for setups requiring extra rigidity and clamping force—especially in sinker EDM and precision CNC milling. 

Which Should You Choose? 

Choose EROWA-Compatible Tooling if you: 

• Need high rigidity and strong palletization for heavier setups 

• Run sinker EDM or high-force CNC operations 

• Want to ensure tight clamping with minimal deflection 

• Prefer ITS-style pre-mounted electrode holders 

Choose System 3R-Compatible Tooling if you: 

• Prioritize speed, flexibility, and faster job changeovers 

• Use wire EDM or do high-mix machining 

• Rely on multi-part fixtures or robotic pallet systems 

• Need a reliable and widely adopted macro-based standard 

At Rapid Holding Systems, you can mix and match without the stress. Our entire product line includes both Erowa ITS and System 3R Macro compatible tools, designed to reduce lead times, cut costs, and get your machines back to producing—fast. 

🛠️ Save 40–50% compared to OEM pricing with zero compromise on precision or durability. 

Explore our full range of Erowa and System 3R compatible tools. www.rapidholdingsystems.com

Or chat with our team for a free consultation—we’ll help you build the right setup for your shop.  

For over 35 years, Circle 5 has been a trusted name in the manufacturing and prototyping industry. Specializing in machining ferrous and non-ferrous metals, they have consistently invested in cutting-edge CNC and EDM technologies to stay ahead of the competition. 

However, as their operations expanded, Circle 5 faced increasing challenges with their EDM workholding systems—leading to inefficiencies, rising scrap rates, and longer setup times. Determined to find a better solution, they turned to Rapid Holding Systems, and the results were game-changing. 

Inefficiencies and Inconsistencies in EDM Workholding 

Before working with Rapid Holding Systems, Circle 5 struggled with several critical challenges that impacted their productivity and bottom line: 

Inefficient Setup Times 

“We were using manual chucks on the table before, but now we’ve switched over to multiple air chucks. It’s been a game-changer for us.” 

The old manual chuck system required frequent adjustments, leading to extended setup times and machine downtime. Operators spent too much time fine-tuning setups instead of focusing on production. 

Inconsistent Workholding Precision 

“With the old system, the turret handle would work its way loose, causing inconsistencies. But now, with the new system, it’s a lot more rigid and repeatable.” 

The manual system’s lack of repeatability led to part movement, resulting in poor precision and increased scrap. 

Difficulty Machining Deep and Complex Parts 

“The biggest issue was getting down into deep pockets and small areas. The custom extensions from Rapid Holding Systems solved that perfectly.” 

Standard workholding solutions couldn’t effectively secure parts for deep cavity machining, forcing the team to find workarounds that were inefficient and unreliable. 

Pneumatic Chucks and Custom Workholding Extensions 

Recognizing the need for a modern and efficient solution, Circle 5 implemented Rapid Holding Systems’ pneumatic chuck workholding system, which provided: 

• Faster and More Repeatable Setups 

By switching from manual chucks to multiple pneumatic chucks, operators were able to secure parts with ease, reducing setup times and maximizing machine uptime. 

• Enhanced Clamping Precision 

The pneumatic chucks offered a more consistent and secure hold, eliminating the manual handle issues and improving repeatability. 

• Custom Extensions for Deep Cavities 

With custom-designed extensions tailored to their needs, Circle 5 could now machine deep pockets and intricate geometries with confidence. 

“Now we can get all the way down into the deep cavities without losing accuracy. It’s been a game-changer.” 

• Reduced Scrap and Increased Cost Savings 

With better clamping and repeatability, Circle 5 experienced fewer rejected parts and improved cost-efficiency. 

Greater Efficiency and Cost Savings 

By adopting Rapid Holding Systems’ workholding solutions, Circle 5 achieved: 

• 30% Reduction in Setup Time 

• Faster setups allowed them to increase machine utilization and take on more projects. 

• Significant Scrap Reduction 

With better workholding precision, they minimized material waste and improved overall profitability. 

• Improved Operator Efficiency 

Easier, more intuitive workholding reduced operator fatigue and improved workflow. 

“We were burning through a lot of parts before, but with the new holding system, we’ve reduced scrap significantly and saved the company money.” 

Video: https://www.youtube.com/watch?v=YauNdKdQTcM 

Ready to Optimize Your EDM Workflow? 

Are you facing similar workholding challenges in your shop? At Rapid Holding Systems, we specialize in custom solutions that improve precision, reduce downtime, and boost profitability. 

📞 Contact us today to find the right solution for your machining needs. 

#EDM #CNC #ManufacturingSuccess #WorkholdingSolutions #PrecisionMachining #Circle5Success