12/23/2019 | 1 MINUTE READ

Is 3D Printed Tooling a Solution for Die Casting?

Facebook Share Icon LinkedIn Share Icon Twitter Share Icon Share by EMail icon Print Icon

After tackling the 3D printer, material and design, there's still one challenge left for Exco Engineering: convincing customers. 


Facebook Share Icon LinkedIn Share Icon Twitter Share Icon Share by EMail icon Print Icon

Die casting is a particularly harsh operation. The process involves forcing molten metal into a mold cavity at high pressure, and is commonly used to make automotive parts such as engine blocks, wheels and engine cradles. The tooling that produces these parts must be durable, and buyers are not likely to trust a new process easily. In other words, die cast tooling is not an obvious place to experiment — but the challenge of the process makes it exactly the kind of application that is ideal for testing the limits of metal 3D printing. 

This is what Exco Engineering (located in Toronto) has done over the last four years. In an initiative led by Wes Byleveld, now director of additive manufacturing, the company has not only proven that 3D printed tooling can withstand the die cast process, but that it also provides benefits to that process in the form of better cooling, reduced cycle time and longer tool life.

Wes Byleveld, director of additive manufacturing, Exco Engineering

Wes Byleveld, director of additive manufacturing, stands near one of Exco Engineering’s EOS metal 3D printers. The company currently owns two for its die cast tooling work, and could add more in the future. 

Getting to this point has been an uphill battle. Steps along the way have involved finding the right metal printer that could handle the work; a change in material; and pushing the limits of conventional design rules with simulation. Mr. Byleveld and his team still aren’t finished. The challenge Exco faces now? Explaining to customers the value that this 3D printed tooling offers.

November 2019 Additive Manufacturing magazine

Read the full story of Exco’s journey into 3D printed die cast tooling in this story from Senior Editor Brent Donaldson.

Read More in Additive Manufacturing 


This article is the cover story of Additive Manufacturing’s November/December 2019 issue. Check out the digital edition for this story and others covering AM for aerospace, 3D printed cutting tools, better brackets and more.

Want to learn more about industrial 3D printing and additive manufacturing? Subscribe and never miss an issue. 


  • A Model Camshaft Grinding Process

    Optimizing a camshaft lobe grinding cycle has traditionally been based less on science and more on educated guesswork and numerous test grinds. Now, computer thermal modeling software can predict areas where lobe burning is likely to occur, in order to determine the fastest possible work speed that won't thermally damage lobes and greatly reduce the number of requisite test grinds.

  • 3D Scanning: Reproducing One-Of-A-Kind Prototypes

    A laser scanning system helps this shop capture the free-form surfaces on a hand-sculpted original. The resulting digitized models are the basis for CAM applications such as programming a CNC machining center. 

  • Another Angle On HSM

    The savings in setup time were welcome enough, but this mold maker found that a 3+2 machining center also accelerated its use of high speed machining.