Our additive manufacturing technology offers unmatched efficiency, providing low-volume, high-quality tooling that conventional methods simply cannot replicate.
ADVANCED MANUFACTURING
Engineering First
Exco Additive is part of Exco Engineering, a world leader in the design, build and development of large high pressure die cast tooling, operating out of a 130,000 sq ft facility equipped with modern machine tools and leading operational processes.
State-of-the-art equipment
Multiple 4-laser 3D printers
In-house proprietary heat treating
5-axis CNC machines
Sawing center
Efficiency Through Smarter Tooling
In die casting, conformal cooling reduces cycle times, lowers scrap rates, and improves thermal consistency shot after shot. Near-net-shape manufacturing cuts the raw material waste that conventional machining leaves behind. The same principles that transform die casting performance are already at work across a growing range of demanding industries.
Process Optimization Through Additive Manufacturing
The value of additive manufacturing extends beyond part production. By improving heat transfer, thermal management, and tooling performance, AM enables more stable and resource-efficient manufacturing processes across a wide range of high-demand industrial applications.
Beyond Die Casting
We focus on applications where additive manufacturing enables:
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Geometry impossible through conventional machining
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Improved thermal management and heat transfer
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Reduced process variability and scrap
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Longer tooling life under extreme operating conditions
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Higher production efficiency over long manufacturing cycles
Aerospace
AM in aerospace is driven by lightweighting and part consolidation. Regulatory bodies like FAA/EASA are increasingly certifying AM parts.
Defence
AM delivers the on-demand production, design freedom, and material performance that defence systems demand, from structural components to pressure-critical hardware.
Nuclear
AM offers complex pressure-retaining components produced to nuclear-grade standards, without the lead times or minimum quantities of traditional manufacturing. Critical for replacing components that are decades old and hard to source.
Injection Moulding
By enabling conformal cooling channels that follow the mould geometry exactly, AM eliminates hot spots, reduces cycle times, and dramatically cuts warpage and scrap.
Semiconductor & Electronics Manufacturing
Chip fabrication equipment demands extreme dimensional stability and exacting tolerances. High part value and low production volumes make AM the natural fit technically and economically.
Motorsport & High Performance Automotive
Low volumes and high complexity make this a classic AM market. Less about sustainability and more about performance, it's a proving ground that feeds credibility into mainstream automotive.
