You have one vacuum source. You have AnchorPod on top of the bench. You have side-mounted pods for edge work. You have a track saw rail you clamp down occasionally. Maybe you're adding face frame pods soon.
Right now, every time you switch from one task to another, you're unplugging hoses, moving lines, restarting the pump, and losing vacuum across the entire bench. You stage the next workpiece, but you can't prep it until the current piece is done because there's only one zone and it's either on or off.
Bench zoning solves this. One vacuum source. Multiple independent zones. Each zone controlled separately. You work on one setup while staging the next. You isolate what you're using and keep unused lines sealed. You hit a single release valve and dump vacuum safely before lifting anything.
This is how you build a vacuum workholding system that scales with your workflow instead of fighting it.
What Bench Zoning Actually Means
Zoning is independent vacuum control for different areas of your bench.
Example setup:
- Zone 1: AnchorPod (top of bench, flat panel work)
- Zone 2: BenchGrip pods (vertical edge work, narrow stock)
- Zone 3: ComponentGrip FS Rail pods for your track saw (occasional clamping for long cuts)
- Zone 4: Harpyie narrow pods for face frame applications (repetitive narrow operations)
Each zone has its own valve. Open Zone 1, and vacuum flows to AnchorPod. Open Zone 2, and side pods engage. Close Zone 3, and the track saw line stays sealed even while other zones are active.
Why this matters: You stage your next workpiece on side-mounted pods while your current piece is held on AnchorPod. No power-cycling the pump. No hose swapping. No waiting. One task flows into the next because the system is designed for it.
Without zoning, your entire bench is one zone. Everything is on or everything is off. You can't prep the next piece until the current piece is released. You lose time fighting the system instead of working.
The Three Functions of a Zoned System
A proper bench hub does three things:
1. Route
Distribute vacuum from one source to multiple endpoints. One pump. Four zones. Your vacuum capacity doesn't multiply, but your workflow capability does.
2. Isolate
Control zones independently. Zone 1 is active while Zones 2, 3, and 4 stay sealed. No pressure loss. No cross-contamination. Open only what you need.
3. Release
Fast, controlled vacuum dump. Hit the master release, and every active zone bleeds down in seconds. Safe repositioning. No workpiece shifting under partial vacuum. No manual vent hunting.
These three functions are what separate a vacuum system from a vacuum workflow.
Anatomy of a Bench Hub Setup
A basic 4-zone system starts with a vacuum source—either a dedicated vacuum pump for bench-anchored setups, or Nexus + Grabo for portable work with lower sustained capacity. From there, vacuum flows through a master release valve positioned upstream before any zones. This release gives you a one-motion dump for all active lines when you need to safely reposition workpieces.
Next comes the splitter or manifold, which distributes vacuum to 2, 3, or 4+ lines using push-to-connect fittings for tool-free routing. Each line feeds into a per-line isolation valve—one valve per zone. Close the valve and that zone is sealed. Open it and vacuum flows.
Finally, each valve connects to an endpoint: AnchorPod on top of the bench, side-mounted BenchGrip pods for edge work, ComponentGrip FS Rail pods for track saw clamping, or face frame Harpyies for narrow stock operations.
Plumbing Order & Best Practices
The recommended signal path is straightforward: Source → Master Release → Splitter → Per-Zone Valves → Endpoints.
This order matters. The release sits upstream so one motion dumps all zones. The splitter comes after the release so all lines get equal vacuum distribution. Valves come after the splitter so each zone controls independently without affecting the others.
Where you mount the hub depends on your workflow. Front-of-bench mounting is accessible and makes hitting the release easy, but it can interfere with long workpieces. Under-table mounting keeps everything clean and out of the way, but requires reaching or routing the release handle to the front. For Dashboard users, side-rail mounting tucks the hub under the lower rail while keeping it accessible from your operator position.
Line routing is where you save yourself headaches later. Keep runs as short as practical from source to endpoint—longer runs increase pressure drop. Avoid sharp bends and kinks in the tubing. Label each zone at the valve (Pods A/B, Rail, Face Frames) so you're not guessing six months from now. Use coiled line for mobile endpoints like shaper plates or portable rail work so you have slack when you need it.
Leak testing isn't optional. Cap one zone output and verify the others hold vacuum independently. Listen for hissing at fittings. Run a soapy water test on threaded connections if you're paranoid (you should be). Poorly sealed ports degrade holding performance across all zones because vacuum doesn't care about your intentions—it finds the leak.
Common Configurations
You don't need four zones on day one. Start with the configuration that matches your current workflow, then expand as new operations demand it.
2-Line Mini Setup
One vacuum source, two zones. Zone 1 feeds AnchorPod on top of the bench for flat panel work. Zone 2 feeds a pair of side-mounted BenchGrip pods for edge operations. Add a master release valve upstream and you're done. This setup handles 80% of what most small shops encounter: flat work, edge work, and the ability to stage one while holding the other.
4-Line Standard Setup
Same vacuum source, four independent zones. Zone 1 is still AnchorPod. Zone 2 is still side pods. Zone 3 adds ComponentGrip FS Rail pods for track saw clamping or long-stock work. Zone 4 adds Harpyie narrow pods for face frame operations or repetitive narrow stock processing. This is the configuration that turns your bench into a proper production station—every common operation has a dedicated zone, and you're not fighting for access.
Real Example: Dashboard Workbench
Dashboard setups are purpose-built for zoned vacuum because the dual-channel rail system already positions your workholding in distinct zones. Zone 1 runs to the top-of-bench AnchorPod setup (gasket-based operation, Magnus, or Maximus depending on stock size or application). Zone 2 feeds side-mounted pods on the left rail for vertical edge work. Zone 3 connects to ComponentGrip pods on the right rail for track saw operations. Zone 4 runs to front-mounted Harpyie pods for narrow face frame stock.
Each zone is isolated. You stage the next panel on side pods while the current panel is held on AnchorPod. You clamp your track saw guide without disturbing active zones. You process face frame rails in Zone 4 while Zones 1-3 stay sealed. The bench becomes a workflow engine instead of a single-task station.
Sourcing & Components
You need three types of components: 3-way valves (one per zone plus one master release), a splitter or manifold to distribute vacuum to multiple lines, and push-to-connect fittings with polyurethane tubing.
3-way valves have three ports—P (pressure/source), A (active/zone), and R (release/vent). When open, vacuum flows from P to A. When closed, A vents through R and your zone dumps safely. This is why you get clean, controlled release without manually unplugging lines.
Splitters and manifolds take one input and distribute it to 2, 3, or 4+ outputs. Simple component, critical function—without it, you're back to one zone.
These components are available from Amazon and industrial suppliers. FORG3D can point you in the right direction—for detailed specs, sourcing recommendations, and compatibility notes, see the SYS-GRP Hub FAQ.
Start Simple, Scale as Needed
You don't need four zones on day one. You need one more zone than you have right now.
If you're running a single AnchorPod with no routing, add one side pod and a 2-line splitter. That's it. Now you can stage your next workpiece while the current one is held. That one change cuts dead time by 30% because you're no longer waiting for the pump to cycle between operations.
If you already have top-of-bench and side pods but you're constantly unplugging to switch between them, add isolation valves and a release. Now each zone controls independently and you dump vacuum in one motion instead of fumbling with hose connectors.
If you're adding track saw work or face frame operations, add a third or fourth zone when the workflow demands it—not because the system needs to be "complete." The system is never complete. It grows with your workflow.
This is how you build vacuum workholding that doesn't fight you. One vacuum source. Independent zones. Routing, isolation, and release. You work faster because the system is designed for it.