A New Era of Automotive Manufacturing - the Synergies of Die-Casting & AM: Insights from Wes Byleveld of Exco Engineering
The intersection of tradition and innovation is where true transformation happens, and Exco Engineering stands as a testament to this.
DECEMBER 03, 2024 | Reading time: 5 min
In a recent episode of the Additive Snack Podcast, host Fabian Alefeld sat down with Wes Byleveld, Director of Additive Manufacturing at Exco Engineering, to explore how additive manufacturing (AM) is reshaping high-pressure die casting.
With over two decades of experience, Wes shared the challenges, breakthroughs, and future possibilities of integrating AM into an industry known for its demanding requirements.
Exco Engineering’s Evolution: Tradition Meets Innovation
Founded in the 1950s, Exco Engineering built its reputation as a leader in high-pressure die casting, focusing on precision and durability. However, as competition from lower-cost global markets intensified, Exco recognized the need to adopt forward-thinking strategies to maintain its edge.
Under Wes Byleveld’s guidance, Exco began exploring AM as a way to overcome the limitations of conventional tooling methods. The company’s early adoption of AM wasn’t without challenges, but Exco has enhanced its ability to deliver complex, high-performing components while maintaining the high standards expected in the automotive sector.
Wes explained on the podcast how Exco’s decision to invest in AM was driven by necessity:
“The die casting industry is incredibly competitive. To stay ahead, we needed to look beyond traditional methods and focus on innovation. Additive manufacturing became a natural fit for addressing challenges like complex geometries and tighter tolerances.”
The Role of AM in High-Pressure Die Casting
At its core, high-pressure die casting is a process of precision and endurance. Molten metal is injected into a mold under immense pressure, resulting in components that must meet stringent requirements for strength and reliability. However, traditional manufacturing methods can fall short when faced with increasingly complex geometries, demanding thermal conditions, and the need for faster production cycles.
AM offers a solution to these challenges by enhancing the die casting process with unprecedented design freedom and functionality. Exco Engineering, under Wes Byleveld’s leadership, uses AM to produce specialized inserts — critical components within the molds that experience the most wear and thermal stress. These inserts often incorporate conformal cooling channels, which are custom-designed to optimize heat dissipation. Unlike conventional drilled cooling channels, conformal channels follow the contours of the part, enabling faster cooling and reducing defects like porosity and die solder.
“We started by testing inserts in particularly challenging areas of production, where traditional methods struggled to meet performance standards,” Wes explained. “The results were clear — additive could not only match but exceed conventional methods in certain applications.”
Wes also highlights measurable improvements in performance and consistency, particularly in complex applications like engine blocks and transmission cases. For an in-depth look at Exco’s use of AM in automotive tooling, this case study provides compelling insights into their process.
Challenges in Combining AM With Die Casting
While the benefits of AM in high-pressure die casting are clear, the journey to full integration is not without its hurdles.
One of the primary obstacles is cost. AM’s upfront expenses — ranging from machine investments to the higher price of materials like maraging steel — can be a deterrent for manufacturers accustomed to traditional methods. As Wes pointed out, convincing stakeholders often requires demonstrating the long-term return on investment. “It’s easy to focus on the initial cost of an AM insert, but when you calculate the reduction in scrap, downtime, and maintenance, the value becomes undeniable,” he explained.
Another significant challenge lies in overcoming industry resistance to change, particularly in regions where traditional practices dominate. In Europe, for example, older specifications for die materials like H11 and H13 still hold sway, despite advancements in printable materials with comparable or superior properties. Changing such entrenched standards requires extensive education and successful case studies to build trust and acceptance.
Additionally, the adoption of AM requires a deep understanding of both the technology and its applications. This includes optimizing machine uptime, managing powder supply chains, and addressing the technical complexities of integrating AM components with conventionally manufactured parts. Exco has mitigated these challenges through careful planning, in-house expertise, and close collaboration with customers.
Despite these hurdles, Wes remains optimistic: “Each challenge is an opportunity for growth. As the technology advances and costs decrease, I believe we’ll see even broader adoption across the die casting industry.”
Beyond Inserts: Additional Applications of AM in Die Casting
While conformal cooling inserts are a flagship application of AM in high-pressure die casting, Exco Engineering has found other innovative ways to leverage the technology. One such advancement is the creation of custom manifolds to streamline waterline management.
In traditional die casting setups, molds can contain hundreds of individual waterlines, each requiring multiple fittings and hoses. These components not only complicate assembly but also increase the potential for leaks — an unacceptable risk in molds that can weigh several hundred thousand pounds and take days to replace. To address this, Exco uses AM to design compact, integrated manifolds that combine multiple waterlines into a single system. This significantly reduces the number of leak points, enhances reliability, and simplifies maintenance.
The Future of AM in Die Casting
As AM becomes more integrated into high-pressure die casting workflows, its potential to revolutionize the industry continues to grow. Wes Byleveld foresees a future where AM plays an even more prominent role, driven by advancements in technology and evolving industry demands.
One exciting prospect is the development of larger build platforms and more powerful laser systems, which could enable the production of entire molds or significantly larger components. This would reduce reliance on traditional machining and assembly processes, streamlining operations and cutting lead times. “The idea of fully additively manufactured molds may seem far off, but with the current pace of innovation, it could become a reality within a decade,” Wes predicted.
Material science is another area poised for breakthroughs. The introduction of new printable materials with enhanced properties, such as improved wear resistance or better thermal conductivity, could address some of the current limitations of AM in die casting. Wes also highlighted the potential for artificial intelligence to accelerate material development and simulation processes, allowing manufacturers to identify optimal solutions more quickly and accurately.
For Wes, the future of AM in die casting is both challenging and exciting. “We’re just scratching the surface of what’s possible,” he shared. “The next few years will bring innovations that not only improve processes but redefine how we think about manufacturing as a whole.”
Through insights shared by Wes Byleveld on the Additive Snack Podcast, we see how a blend of traditional expertise and cutting-edge technology can address longstanding challenges while opening the door to new opportunities. As advancements in materials, machine capabilities, and design automation continue to evolve, the future of AM in die casting looks increasingly bright.
For manufacturers seeking to stay competitive in a demanding market, the message is clear: exploring AM isn’t just about keeping up — it’s about leading the way.
Listen and Learn More
Dive deeper into this fascinating discussion by listening to the full episode of the Additive Snack Podcast. Gain firsthand insights from industry experts like Wes Byleveld, and explore how AM is revolutionizing manufacturing processes across industries.
Explore Wes Byleveld’s professional journey on LinkedIn and learn more about Exco Engineering’s groundbreaking work in additive manufacturing.
