# A New Era of Automotive Manufacturing: The Synergy of Die-Casting and AM with Wes Byleveld of Exco Engineering

- Show: [Additive Snack](https://hardwarepodcasts.com/podcast/additive-snack)
- Published: 2024-12-03
- Length: 39m
- Episode: 8
- Page: https://hardwarepodcasts.com/podcast/additive-snack/2024-12-03-a-new-era-of-automotive-manufacturing-the-synergy-of-die-casting-and-am-with-wes
- Listen: https://share.transistor.fm/s/66f8aac0

## Summary

Wes Byleveld, Director of Additive Manufacturing at Exco Engineering, explains how integrating additive manufacturing (AM) with high-pressure die casting solves critical automotive casting issues like porosity and die solder. He details the use of conformal cooling channels in steel inserts to reduce cycle times, eliminate polishing downtime, and remove the need for costly impregnation processes. Byleveld also discusses adoption challenges, including rigid material specifications like H13 steel, and the future potential of automated design, AI-driven material development, and fully additive-manufactured dies.

## Chapters

- [0:07](https://hardwarepodcasts.com/podcast/additive-snack/2024-12-03-a-new-era-of-automotive-manufacturing-the-synergy-of-die-casting-and-am-with-wes#t=7) Introduction: Wes Byleveld and Exco Engineering's history with AM
- [4:57](https://hardwarepodcasts.com/podcast/additive-snack/2024-12-03-a-new-era-of-automotive-manufacturing-the-synergy-of-die-casting-and-am-with-wes#t=297) Evaluating AM for die casting: Tolerances, leak specs, and the first machine purchase
- [11:35](https://hardwarepodcasts.com/podcast/additive-snack/2024-12-03-a-new-era-of-automotive-manufacturing-the-synergy-of-die-casting-and-am-with-wes#t=695) Additive inserts vs. conventional tooling: Conformal cooling and porosity management
- [17:59](https://hardwarepodcasts.com/podcast/additive-snack/2024-12-03-a-new-era-of-automotive-manufacturing-the-synergy-of-die-casting-and-am-with-wes#t=1079) Cost benefits: Reducing polishing downtime and eliminating impregnation processes
- [25:16](https://hardwarepodcasts.com/podcast/additive-snack/2024-12-03-a-new-era-of-automotive-manufacturing-the-synergy-of-die-casting-and-am-with-wes#t=1516) Adoption challenges: Material specifications (H13 vs. maraging steel) and industry resistance
- [31:42](https://hardwarepodcasts.com/podcast/additive-snack/2024-12-03-a-new-era-of-automotive-manufacturing-the-synergy-of-die-casting-and-am-with-wes#t=1902) Future innovations: Cost reduction, material development, and fully additive dies

## Topics

- [Mechanical engineering](https://hardwarepodcasts.com/topic/mechanical-engineering)
- [Materials & manufacturing processes](https://hardwarepodcasts.com/topic/materials-and-processes)
- [Design for manufacturing & NPI](https://hardwarepodcasts.com/topic/design-for-manufacturing)
- [AI & machine learning](https://hardwarepodcasts.com/topic/ai-and-machine-learning)
- [Manufacturing partners & offshoring](https://hardwarepodcasts.com/topic/manufacturing-partners)

## Most relevant to

companies scaling up

## Mentioned

- Exco Engineering (company)
- EOS (company)
- DTW (company)
- H13 (material)
- maraging steel (material)
- H11 (material)

## Related episodes from other shows

- [The Arrival of High-Volume Metal Additive Manufacturing w/ James DeMuth](https://hardwarepodcasts.com/podcast/the-manufacturing-executive/2026-04-07-the-arrival-of-high-volume-metal-additive-manufacturing-w-james-demuth) (The Manufacturing Executive)
- [S1E59 How Oxidation Weakens Aluminum, and Why Engineers Make the World Better | Ogun Unal](https://hardwarepodcasts.com/podcast/being-an-engineer/2020-12-31-s1e59-how-oxidation-weakens-aluminum-and-why-engineers-make-the-world-better-ogu) (Being an Engineer)
- [S6E36 Tessa Axsom | Casting, Metallurgy, & Finishing with Fictiv](https://hardwarepodcasts.com/podcast/being-an-engineer/2025-09-05-s6e36-tessa-axsom-casting-metallurgy-finishing-with-fictiv) (Being an Engineer)
- [Pushing manufacturing boundaries with additive molding](https://hardwarepodcasts.com/podcast/the-manufacturing-executive/2023-01-31-pushing-manufacturing-boundaries-with-additive-molding) (The Manufacturing Executive)
- [Nano Dimension GM Valentin Storz on EMS@C_Level 2022, episode 18](https://hardwarepodcasts.com/podcast/ems-c-level/2022-10-24-nano-dimension-gm-valentin-storz-on-ems-c-level-2022-episode-18) (EMS@C-LEVEL)

## Citing this page

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