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EXCO Engineering is a trusted name for designing and manufacturing large high-pressure die-casting solutions, supplying powertrain, body, and structural component manufacturers worldwide.
Located just 30 minutes from Toronto, the leading global provider operates from a cutting-edge 130,000 ft² facility equipped with modern machine tools and leading operational processes. With their on-site foundry, which includes a state-of-the-art 4,000-ton high-pressure die-cast machine, FANUC robotics, and two furnaces, they efficiently produce both traditional and low-iron aluminum alloys.
With decades of experience, their mission has always been to deliver precision-engineered solutions that exceed customer expectations. As a result, EXCO Engineering has supplied tooling for every major large die-cast automotive component program, including engine blocks (I4, V6, V8), transmission cases (FWD, RWD, CVT), transfer cases, oil pans, wheels, instrument panels, engine cradles, and body panels.
As an industry leader and early adopter, EXCO Engineering quickly recognized the limitations of traditional coordinate measuring machines (CMMs) and manual measurement tools when measuring critical cavity features. The fear of overlooking machining errors and missing engineering changes led them to adopt advanced 3D scanning technology.
Catching Die Crashes In-House, Before They Become Customer Complaints
The quality control team faced challenges when measuring cavities with the CMM, as the traditional probing system could only measure small areas of the cavity, leaving a lot of uncertainty about what lay between those individual measurement points. The probe’s length and ruby size also prevented access to deep ribs and areas beside long core pins.
Visual inspections of complex cavities often missed details. Even with one of North America’s largest CMMs, they still struggled to inspect some of their largest die shoes—knowing their die-casting solutions would only continue to grow in size.
They feared overlooking critical features, which could result in a die crash at the customer's foundry and potentially halt production. Finding a better way to inspect these critical cavity features was necessary to identify potential issues in-house before they turned into customer complaints.
Accurate Results, the Key to Adopting 3D Scanning
Realizing that the CMM had limitations and adopting 3D scanning wasn’t easy—operators were initially hesitant to trust the new technology. Building that confidence took time, but delivering reliable results was key. By establishing clear processes and standards, users consistently achieved accurate measurements, reinforcing their trust in 3D scanning. Today, new users quickly adopt 3D scanning, making onboarding smoother than ever.
EXCO Engineering partnered with Creaform to refine and standardize their processes for greater repeatability. With the addition of the second MetraSCAN 3D scanner, users immediately noticed improved accuracy, boosting their confidence in the scan results.
"With the CMM, it seemed like we were looking at a molding area with one of the first black & white TVs. Now, after we implemented Creaform’s scanning software using the MetraSCAN 3D in our daily activities, it seems like we are seeing the results in 4K as we can clearly see what’s going on."
Jonathan Koot, Quality Systems Manager, EXCO Engineering
Detecting What Traditional Methods Missed with 3D Scanning
It didn’t take long for EXCO’s operators to scan complex die shoes the CMM could not reach and uncover errors invisible to traditional methods—and that only 3D scanning could detect. This capability enabled them to investigate issues in depth and refine their programming, machining, and polishing processes.
Today, 3D scanning is not just a tool for measuring conformity—it’s an integral part of their continuous improvement strategy, making their operations faster, more reliable, and competitive in a demanding global market.
Leading the Way in Accuracy, Portability, Versatility and Speed
As more 3D scanning companies entered the market, EXCO Engineering remained committed to Creaform, recognizing its continued leadership in accuracy, portability, versatility, and speed. Their exceptional customer support further reinforced this decision.
With the ability to bring the 3D scanner wherever needed, operators could scan parts directly on the shop floor, inside CNC machines, or even while suspended in the air and moving on a crane. They can also effortlessly measure larger, more complex parts with the MetraSCAN 3D scanner and Portable CMM, which was previously impossible despite having one of the largest CMMs in North America.
Moreover, 3D scanners capture entire surface profiles rather than just points, resulting in more complete, accurate, and reliable analyses. Full visual colormaps make deformations easy to identify, improving report sharing and collaboration across departments.
The quality team also found Creaform’s Inspection software—part of the Creaform Metrology Suite—significantly more intuitive and straightforward than other inspection software, allowing them to perform accurate inspections and analyze entire cavity surfaces effortlessly. Instead of waiting hours, they could now generate full visual reports in minutes, streamlining their workflow and enhancing productivity.
"Creaform leads the way in developing and improving portable 3D scanning. Whether it’s the speed, accuracy, or software, I have witnessed the continual improvement that Creaform strives for."
Jonathan Koot, Quality Systems Manager, EXCO Engineering
A Partnership that Changed Everything
Partnering with Creaform has revolutionized EXCO’s processes. By scanning parts directly on the shop floor, the operators could immediately detect missing engineering changes or parts with the wrong geometry, and identify the necessary corrections to fix them. As a result, the EXCO quality team has eliminated critical errors before they reached customers.
With Creaform 3D scanners, EXCO Engineering not only prevented costly die crashes and the shipment of incorrectly shaped parts but also saved valuable operational time by cutting inspection time in half for certain parts.
Creaform’s customer support has also been instrumental to EXCO’s success in the market. Whenever the operators and quality team had an issue or question, Creaform technicians responded quickly—providing answers or even offering hands-on, one-on-one training on-site.
"Personally, I have found Creaform’s support to be absolutely amazing. They set the bar so high that I forget what normal support is like. Most, if not all, problems are solved in a short amount of time, and support always seems to be available for immediate contact."
Jonathan Koot, Quality Systems Manager, EXCO Engineering
Driven by innovation and precision, EXCO Engineering partnered with Creaform to elevate the quality of its large high-pressure die-casting solutions. With Creaform’s cutting-edge 3D scanning technology and unrivaled support, EXCO delivers quality and performance to customers worldwide—ensuring every casting produced with its solutions meets the highest standards.
Published 04/08/2025