Western bean cutworm, Striacosta albicosta (Smith; Lepidoptera: Noctuidae) has become a key pest of maize, Zea mays (L.), in Ontario, Canada which is challenging to control due to its lack of susceptibility to most Bt-maize events. Injury by S. albicosta may exacerbate Fusarium graminearum (Schwabe; Hypocreales: Nectriaceae) infection through provision of entry points on the ear. The objectives of this study were to: investigate the relationship between injury by S. albicosta and deoxynivalenol (DON) accumulation; evaluate non-Bt and Bt-maize hybrids, with and without insecticide and fungicide application; and determine optimal insecticide-fungicide application timing for reducing S. albicosta injury and DON accumulation. The incidence of injury by S. albicosta and ear rot severity were found to increase DON concentrations under favorable environmental conditions for F. graminearum infection. Incidence of S. albicosta injury was more important than severity of injury for DON accumulation which may be due to larval consumption of infected kernels. The Vip3A × Cry1Ab event provided superior protection from the incidence and severity of S. albicosta injury compared to non-Bt or Cry1F hybrids. Insecticide application to a Vip3A × Cry1Ab hybrid did not reduce injury further; however, lower severity of injury was observed for non-Bt and Cry1F hybrids when pyrethroids or diamides were applied at early VT or R1 stages. DON concentrations were reduced with application of prothioconazole fungicide tank-mixed with insecticide at late VT (before silk browning) or when insecticide was applied at early VT followed by prothioconazole at R1. The application of an insecticide/fungicide tank-mix is the most efficient approach for maize hybrids lacking high-dose insecticidal proteins against S. albicosta and F. graminearum tolerance. Results demonstrate that reducing the risk of DON accumulation requires a strategic approach to manage complex associations among S. albicosta, F. graminearum and the environment.