Castle USA Production pocket joinery for ANY shop - Castle USA.
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Production pocket joinery… for ANY shop.
Castle USA
Castle USA
About Us
Castle USA has been making pocket cutting machines since 1985. We make and assemble everything
in Petaluma, California, and our products are manufactured to the highest standards. We use local
vendors wherever possible and as an American machinery manufacturer, Castle champions the cause
of the American entrepreneurial woodworker. We develop products that support woodworking shops
of all sizes in their efforts to be productive and successful.
It all started when founder Max Durney, then a partner at an architectural millwork firm, was trying to
find an assembly solution for store fixtures he was shipping overseas. Max wanted to produce fixtures
that could be shipped flat, site-assembled, and which would have strong, stable joints when put
together. Max solved his dilemma by creating an entirely new joinery method: pocket cutter joinery.
This new method included machining a pocket using a router, drilling a pilot hole from the opposite
side, and then fastening the parts with screws through the pocket into the adjoining part.
Many years and numerous patents later, Max’s solution is still known today, industry-wide, as the
“Castle low-angle pocket.”
At Castle, our dedication to quality, service, and support is evidenced in our products and in our loyal
customer base. We strive to always deliver value to our customers, market partners, suppliers, and
employees.
Why Castle?
Castle was awarded the very first patent for pocket cutting technology. And, as the result of Castle’s
continued product innovations and improvements, many additional patents have been awarded to us
for our expanded range of pocket cutters and for our latest machine, the CSI 1.5D Pocket Cutter/Screw
Inserter. We also manufacture world-class assembly tables, accessories, and tooling.
A few things, however, have never changed here at Castle. Our products are virtually unsurpassed
when it comes to service life, durability, ease of maintenance and simplicity in user training. Just about
anyone can master any of our machines with minimal training. We are committed to our customers,
dealers, and machine operators, and take pride in our friendly and effective customer service. We are
pleased to have contributed to the ever-growing use of pocket joinery.
The Castle, Low-Angle Pocket
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of drilled (high-angle) pockets
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to the pocket, and its low-angle reduces joint shift, creating a more stable joint
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material from getting trapped in the joint preventing good joint tightness.
Production pocket joinery… for ANY shop.
1364 N. McDowell Blvd
Castle USA
Suite #1
Petaluma, CA 94954
800.282.8338
TSM-12 Pocket Cutter Machine
The TSM-12 benchtop pocket cutter machine
routs the 6 degree, low-angle Castle Pocket
with no tear out in less than 2 seconds. The
superior low screw angle minimizes joint shift
while providing strong, stable joints.
Because the TSM-12 uses standard 110V
electric and does not require any shop air, it’s
ideal for jobsites, small shops, or the weekend
woodworker.
Each TSM-12 is equipped with a Bosch 1617
Router with a 3/8” three-flute solid carbide
router bit for cutting the pocket and a Bosch
Colt Router with a 9/64” premium drill bit for
drilling the pilot hole. The TSM-12 comes
ready-to-go and delivers Castle quality with
every pocket it cuts.
FEATURES AND BENEFITS INCLUDE:
rCuts the Castle low-angle pocket, for strong, stable, tight, and rAdjustable web for handling various pocket screw lengths
superior joints rIntegral work clamp and pocket cutting lever are
rEquipped with: ergonomically positioned for fast pocket cutting
rBosch 1617 Router with a 3/8” three-flute solid carbide router bit rIntegrated, 4” and Shop Vac dust ports for minimizing
for cutting the pocket dust and debris
rBosch Colt Router with a 9/64” premium drill bit for drilling the rEasy maintenance and bit changing
pilot hole rRequires only basic, 110V power
rLow-angle pockets minimize the need for clamping during assembly rDurable, solid surface work top
rWider throat opening for thicker stock – accommodates stock from rTSM-12 comes fully assembled, factory tested, and ready
1/2"to 1-1/2" thick to work
800.282.8338 I www.CastleUSA.com
1364 N. McDowell Blvd
Castle USA
Suite #1
Petaluma, CA 94954
800.282.8338
TSM-12 Pocket Cutter Machine (continued)
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rRouter: Bosch 2.0hp #1617EVS for drilling pilot holes
rDrill: Bosch Colt 1.0hp #PR20EVS for drilling pilot holes
rRouter Bit: Premium 3/8” Solid Carbide, Rough Mill
rDrill bit: 9/64” Brad and Spur Premium TiN-Coated Bit
rPower req: 110V, 15 amps
rShipping weight: 65 lbs
rFootprint: 13.5" width x 20" depth x 20" high
rManufactured in the USA
*Actual brands and models are dependent on 3rd party suppliers.
800.282.8338 I www.CastleUSA.com
1364 N. McDowell Blvd
Castle USA
Suite #1
Petaluma, CA 94954
800.282.8338
TSM-22 Pocket Cutter Machine
The TSM-22 is our best-selling pocket cutter
machine - its design and durable build has made
it a clear favorite among professionals in cabinet
making, furniture making, and woodworking.
The TSM-22 clamps the stock, routs a pocket,
and drills a pilot hole with a tap of the foot
pedal.
The TSM-22 creates fast, strong, stable butt
joints, is easy to use, and requires minimal
maintenance. Use the TSM-22 with composites,
panel, hard or soft wood. Requiring minimal
training, the TSM-22 uses standard 110V
electric, and is ready-to-go upon delivery.
FEATURES AND BENEFITS INCLUDE:
rCuts the Castle low-angle 6 degree pocket, for strong, stable, rStandard machine height with a small footprint -
tight, and superior joints easy to fit into any shop
rDesigned for professional, production joinery for maximum rEasy maintenance and bit changing
throughput of stackable parts rMinimal shop air required: 85 psi
rLow-angle pockets minimize the need for clamping during assembly rIntegrated, 4” dust port for minimizing dust and debris
rCuts pocket and pilot hole in a single cycle, increasing throughput rRequires only basic, 110V power
and decreasing material damage and waste rTSM-22 comes fully assembled and ready to work –
rFootswitch with automated operation that’s simple and easy to use quickly integrate into any existing production process
rAdjustable for different sized webs or work-flow
800.282.8338 I www.CastleUSA.com
1364 N. McDowell Blvd
Castle USA
Suite #1
Petaluma, CA 94954
800.282.8338
TSM-22 Pocket Cutter Machine (continued)
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rRouter: Bosch 2.0hp #1617EVS for pocket cutting
rDrill: Bosch Colt 1.0hp #PR20EVS for drilling pilot hole
rRouter bit: Premium 3/8” Solid Carbide, Rough Mill
rDrill bit: 9/64” Brad and Spur Premium TiN-Coated Bit
rPower req: 110V, 15 amps
rAir req: 85 psi
rBasic footprint: 31.5“ depth x 30” width x 48" high
rWorking height: 36.5“
rShipping weight: 1,085lbs
r4” integrated dust port
rManufactured in USA
*Actual brands and models are dependent on 3rd party suppliers.
800.282.8338 I www.CastleUSA.com
1364 N. McDowell Blvd
Castle USA
Suite #1
Petaluma, CA 94954
800.282.8338
TSM-30 Series
Pocket Cutter Machines
Designed for continuous production in cabinet
manufacturing, furniture plants, mobile home
factories, and more, the TSM-30 Series Pocket
Cutters are available in three different voltage
options:
r220V Single Phase (TSM-31 220V)
r230V Three Phase (TSM-35 230V)
r460V Three Phase (TSM-35 460V)
Each cuts the patented, six-degree, Castle
low-angle pocket and includes adjustable
and retractable stop features, exclusive
to Castle.
TSM-30s are extremely well-suited for multi-shift
production in a broad variety of woodworking
manufacturing environments.
FEATURES AND BENEFITS INCLUDE:
rCuts the Castle low-angle pocket, for strong, stable, tight, rStandard machine height with a small footprint - easy to
and superior joints fit into any production line
rDesigned for high-capacity, continuous production joinery rEasy maintenance and bit changing
for maximum throughput of stackable parts rMinimal shop air required: 85 psi
rLow-angle pockets minimize the need for clamping during rFootswitch with automated operation that’s simple and
assembly easy to use
rCuts pocket and pilot hole in a single cycle, increasing rTSM-30 series machines come fully assembled and ready
throughput and decreasing material damage and waste to work – quickly integrate into any existing manufacturing
rAdjustable indexing stops are built into the top, and process or work flow
automatically recess below the table
800.282.8338 I www.CastleUSA.com
1364 N. McDowell Blvd
Castle USA
Suite #1
Petaluma, CA 94954
800.282.8338
TSM-30 Series (continued)
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Heavy duty induction motors drive the pocket cutting spindles: the TSM-31 uses a 220V, single phase induc-
tion motor and the TSM-35 models use three phase induction motors in either 230V or 460V. All models use
a high-torque, heavy-duty air motor - specifically designed for Castle - to drive the pilot bit. Both operations -
pocket cutting and pilot hole drilling - are completed in a single cycle.
TSM-30 series feature heavy duty construction throughout, with easy, top-down access for quick tooling
changes. Adjustable indexing stops are built into the top - and exclusive to Castle, they automatically recess
below the table for quick part transitions during high production shifts. These premier woodworking shop
tools can produce more than a quarter million pockets per month for years on end with minimal maintenance.
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rMotor: 1.5hp Baldor Router Motor (TSM-31 220V), 1hp Leeson Router Motor (TSM-35 230V and TSM-35 460V)
rRouter bit: Premium 3/8” Solid Carbide, Rough Mill
rDrill: Sioux SDG10S25FCT Air Motor
rDrill bit: 9/64” Brad and Spur Premium TiN-Coated Bit
rPower Options: 220V Single Phase; 230V Three Phase; 460V Three Phase
rAir req: 85 psi - external regulator, filter and lubricator included
rBasic footprint: 21” depth x 19” width
rWorking height: 36.5”
rWorktop usable area: 16” depth x 18.5” width
rMachine height: 38”
rShipping weight: Approx. 340 lbs
rManufactured in the USA
800.282.8338 I www.CastleUSA.com
1364 N. McDowell Blvd
Castle USA
Suite #1
Petaluma, CA 94954
800.282.8338
CSI 1.5D
Pocket Cutter/
Screw Inserter Machine
Castle’s CSI-1.5D Pocket Cutter/Screw
Inserter saves time, reduces waste, and
eliminates non-value-added labor in high-
capacity production joinery. Pockets with
screws, delivered! Using patented Screw-
In-Pocket (SIP) technology, CSI-1.5D cuts
Castle’s distinctive, low-angle screw pocket,
drills a low-angle pilot hole and inserts a
flush screw - all in 1.5 seconds. CSI-1.5D
provides stackable parts in faster production
times by eliminating screw handling at
assembly.
Use the CSI-1.5D with composites, panel
and hard or soft wood.
Optional air table, customizable work decks
and flip stops are available.
FEATURES AND BENEFITS INCLUDE:
rPocket cutter and screw inserter in one step - rLow-angle pockets minimize the need for clamping
patented technology reduces assembly time by 50% during assembly
rCuts the Castle low-angle pocket, for strong, stable, rFootswitch with automated operation is simple and
tight, and superior joints easy to use
rCuts pockets and inserts screws in 1.5 seconds, rCSI-1.5D comes ready to work for fast integration
eliminating non-value-adding labor rCustomizable work decks and flip stops
rDesigned for high-capacity, continuous production rAir table option - perfect for panel and large part production
joinery for maximum throughput of stackable parts rManufactured in the USA
U.S. Patent #6,877,536 | Canadian Patent #2,456,044
800.282.8338 I www.CastleUSA.com
1364 N. McDowell Blvd
Castle USA
Suite #1
Petaluma, CA 94954
800.282.8338
CSI 1.5D (continued)
Castle’s CSI-1.5D Pocket Cutter/Screw Inserter has a super heavy-duty, robust build. It is designed for
continuous production, requiring simple, routine maintenance so that down time is minimized.
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r1.5 second, single operation pocket cutting and screw insertion
rInserted Screws are below flush – parts can be stacked without marring
rWorks with 1-1/4” or 1-1/2” pocket screws
r“Pocket Detect” sensing prevents loaded-pocket, cutting errors
rEasy access to carriages for quick tooling changes
rAdjustable router feed rate optimizes quality and cycle time for various materials
rIncludes solid carbide router bit, drill bit, and dust collection port
rPhenolic worktop and screw feeder platform
rCustomized work deck and flip stops are available
rOptional air table specifically designed for the CSI 1.5D is available for panel/large part
processing, runs on 230V or 460V and extends the work surface on either side to 59”
Key Components*:
rSiemens LOGO! PLC controls
rLCD status display with cycle counter
rPhenolic worktop and screw feeder platform
rVariable frequency drive
rTeknomotor .44HP 220/380 V 18000 RPM drill spindle
rTeknomotor 2.7 HP 220V OR 460V 18000 RPM router spindle
rCastle screw delivery system w/vibratory feeder bowl level sensor
rHeavy duty, Parker Viking Xtreme Series valves w/manual override
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rElectrical: 230V or 460 V/3Ph/20 AMP/60hZ/3 hp Auxiliary 120 VAC supply for screw feeder
rAir: 85 psi with minimum 3/8” ID supply line
rDust collection: 4” duct port
rREQ CFM: 350 CFM with 4” dust collection
rFootprint: 35” x 33” (35” x 63” including Screw Feeder)
rWorking height: 36”
rMachine height: 72”
rWorktop area: 33" depth x 35" width
rShipping weight: 1,025 LBS
rManufactured in the USA
*Actual brands and models are dependent on 3rd party suppliers.
800.282.8338 I www.CastleUSA.com1364 N. McDowell Blvd
Castle USA
Suite #1
Petaluma, CA 94954
800.282.8338
AT-Race 4' x 8' Face Frame Assembly Table
Our Face Frame Assembly Table clamping arm glides
smoothly on an open beam that allows face frames to
extend beyond the top of the table. The redesigned
quick-clamps feature dual handles and centered
activation for easy clamping from either direction.
The rigid steel arm, constructed out of Unistrut, will
stand up to years of use, while the Open Back table
gives you more work area and can handle oversize
frames without taking up valuable shop space.
When you are in need of premier woodworking tools
and supplies, turn to Castle. We pride ourselves on
providing our customers with the absolute best and
highest quality woodworking supplies.
FEATURES AND BENEFITS INCLUDE:
rOpen back design: rBuilt-indriver holster keeps driver within easy reach for
- Accepts oversized frames and other large assemblies increased convenience and efficiency
- Maximizes work area rConvenient, integrated connection port for air-powered
rUnistrut clamping arm with three adjustable air cylinders hold driver adjacent to driver holster
work firmly for easy assembly and minimal sanding rRidgid and lightweight for easier handling and positioning
r45 degree, 1" laminated top for easy glue clean-up and less rFootprint: 113” x 43” x 79”
operator fatigue than horizontal clamping tables rManufactured in the USA
800.282.8338 I www.CastleUSA.com1364 N. McDowell Blvd
Castle USA
Suite #1
Petaluma, CA 94954
800.282.8338
AT-Race 4' x 12' Face Frame Assembly Table
The AT Race 4' x 12' Open-Back Face Frame Assembly
Table features redesigned quick-clamps with center
mounted switching for easy access from both sides.
The clamp arm is steel ensuring a long lasting lifespan.
The stainless steel bottom bracket features an air driver
holster built right in.
The open back feature gives you more work area and
can handle oversize frames without taking up valuable
shop space.
This assembly table is an essential addition to your
inventory of professional woodworking tools.
FEATURES AND BENEFITS INCLUDE:
rOpen back design:
- Accepts oversized frames and other large assemblies rBuilt-indriver holster keeps driver within easy reach for
- Maximizes work area increased convenience and efficiencyncy
rTwo unistrut clamping arms with three adjustable air cylinders rRidgid and lightweight for easier handling and positioning
hold work firmly for easy assembly and minimal sanding rFootprint: 165"x43" x 83"
r45 degree, 1" laminated top for easy glue clean-up and less rManufactured in the USA
operator fatigue than horizontal clamping tables
800.282.8338 I www.CastleUSA.comNOTES
Production pocket joinery… for ANY shop.
Made in USA
1364 N. McDowell Blvd Suite #1
Petaluma, CA 94954
800.282.8338
CastleUSA.com
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