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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.
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