In this episode, we explore how cast steel is changing what's possible in structural connection design. We discuss the origins of CAST CONNEX, why traditional fabrication methods can struggle with complex connection geometries, and how casting can provide new opportunities for structural performance, constructability, and architectural expression.

We also break down how cast steel connections are designed and manufactured, the differences between casting and forging, and where technologies like machining and 3D printing fit into the process. Finally, we go inside the engineering of the Sphere in Las Vegas to explore how cast steel helped solve some of the project's most complex structural connection challenges.

Guest Profile:

Carlos de Oliveira, M.A.Sc., P.Eng., is the co-founder and CEO of CAST CONNEX and a recognized expert in the design and use of steel castings in building construction. The company grew out of Carlos's graduate research at the University of Toronto, where he explored using cast steel to improve structural connections, particularly for seismic applications. Today, CAST CONNEX provides standardized and custom cast steel connections for complex structures around the world, including the Sphere in Las Vegas. Carlos has received numerous awards for engineering innovation and entrepreneurship throughout his career.

Michael Gray, Ph.D., P.Eng., is the co-founder and Executive Vice President of CAST CONNEX. He earned both his bachelor's degree and Ph.D. in structural engineering from the University of Toronto, where his doctoral research focused on cast steel yielding elements for high-ductility structural systems. Michael specializes in nonlinear finite element analysis, seismic design, steel behavior, and complex connection design, and has helped advance the use of cast steel components on major projects around the world, including the Sphere in Las Vegas.

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