In this episode, we talk with Carlos de Oliveira, MASc., P. Eng., president and CEO of Cast Connex, and Michael Gray, Ph.D., P. Eng., executive vice president at Cast Connex, about their journey in revolutionizing connection design engineering through custom steel castings. They discuss key projects like the MSG Sphere and NASA’s Mobile Launcher 2, as well as how their use of non-linear finite element analysis sets them apart.
Engineering Quotes:
Here Are Some of the Questions We Asked Carlos and Michael:
- What inspired you to create Cast Connex, and how did you overcome the early challenges of launching a company centered on disruptive technology?
- What motivated your focus on steel castings in building construction, and what key advantages does this technology bring to the industry?
- How does your application of non-linear finite element analysis contribute to developing innovative structural solutions?
- Could you describe Cast Connex’s involvement in the MSG Sphere project in Las Vegas and highlight any unique challenges you encountered?
- Can you provide an overview of the Mobile Launcher 2 project for NASA’s Artemis Program and explain the role Cast Connex played in its execution?
- How do you envision the future of steel castings in construction, and what role do you see them playing as the industry evolves?
- What are the next steps for Cast Connex as the company continues to grow and innovate?
- What advice would you offer to young engineers starting their careers in today’s industry?
Here Are Some of the Key Points Discussed About How to Utilize Steel Castings in Modern Construction:
- Cast Connex was created out of a desire to provide innovative solutions in connection design engineering through the use of custom steel castings. The early challenges were overcome by carefully managing growth and learning from initial projects. The team partnered with forward-thinking clients who were willing to embrace new technologies. This combination of strategic pacing and innovative collaboration allowed Cast Connex to stand out, offering material efficiency and design flexibility.
- The focus on steel castings in building construction came from their unique ability to provide both design flexibility and material efficiency. Cast Connex controls the alloy composition and heat treatments of its castings, allowing for customization to meet specific project requirements. This enhances the strength and durability of connections, offering a more efficient and aesthetically pleasing alternative to traditional connection methods.
- Non-linear finite element analysis (FEA) plays a crucial role in Cast Connex’s ability to model complex forces and optimize structural components under high stress. This advanced tool allows the company to ensure that its castings meet rigorous performance standards, leading to the development of innovative and functional structural designs that solve complex engineering challenges.
- In the MSG Sphere project, Cast Connex was responsible for designing CNC-machined nodes with precise geometric tolerances to ensure the correct alignment of exterior LED panels. One of the unique challenges encountered was the desert’s extreme temperature fluctuations, which required the structure to be surveyed twice daily and shims to be used to maintain accuracy. Cast Connex’s steel castings were crucial for reducing risks, ensuring precise fabrication and erection, and lowering overall project costs.
- For NASA’s Mobile Launcher 2 project, Cast Connex was tasked with designing structural connections that were both stronger and lighter to meet the demands of launching powerful rockets. The team used its casting process to create complex, internally structured nodal connections with precise tolerances. This approach provided the necessary strength while reducing weight — something that traditional fabrication methods couldn’t achieve.
- The future of steel castings in construction is bright, with its role expected to grow as projects become more complex and demand higher performance standards. Steel castings offer greater design flexibility and material optimization, making them increasingly essential in modern construction. Additionally, emerging technologies like 3D printing and additive manufacturing are set to further expand the capabilities of steel castings, opening new avenues for innovation.
- Cast Connex is focused on expanding its involvement in large-scale projects and exploring cutting-edge technologies like 3D printing in steel. These new technologies align with the company’s expertise in casting, allowing Cast Connex to push the boundaries of connection design and continue delivering innovative solutions to the construction industry.
- Young engineers should remain open to new opportunities and not hesitate to take risks early in their careers. Even if a venture doesn’t succeed, the experience gained is invaluable, and traditional career paths will still be available. It’s important to embrace challenges, explore all possibilities, and even consider entrepreneurial paths, as the lessons learned along the way are crucial for long-term growth.
More Details in This Episode…
About Carlos de Oliveira, MASc., P.Eng.
Carlos de Oliveira, the founding CEO and principal structural engineer of Cast Connex Corporation, is widely regarded as a leading expert in the design and application of steel castings in building construction. He holds a Bachelor of Applied Science in civil engineering from the university of Waterloo and a Master of Applied Science in structural engineering from the university of Toronto.
Carlos is recognized with numerous prestigious awards, including the Ontario Professional Engineers Medal for Entrepreneurship, the Canadian Society for Civil Engineering Excellence in Innovation Award, and the Ontario Centre of Excellence Martin Walmsley Fellowship for Technological Entrepreneurship. He also received the Heffernan/Co-Steel Innovation Fellowship and the CIDECT President’s Award for Research, among other accolades. He is a registered professional engineer in Ontario, Manitoba, Alberta, and British Columbia.
About Michael Gray, Ph.D., P.Eng.
Michael Gray, co-founder and executive vice president of Cast Connex Corporation, is the inventor behind the Scorpion Yielding Connector technology. He holds both his Bachelor of Applied Science and Ph.D. in Structural Engineering from the University of Toronto’s Department of Civil Engineering. His pioneering doctoral research on cast steel-yielding elements in high-ductility, non-buckling braced frames lays the foundation for the Scorpion product line.
Michael is recognized with several prestigious scholarships and fellowships, including the Steel Structures Education Foundation (SSEF) G.J. Jackson Fellowship, the Canadian Institute of Steel Construction John L. Kellerman Fellowship, and the Canadian Society for Civil Engineering Donald Jamieson Fellowship in Structural Engineering. His expertise spans non-linear finite element analysis, seismic design, mechanics, and low-cycle fatigue of steel materials, along with extensive experience in structural engineering and steel connection design.
About the Hosts
Mathew Picardal, P.E., SE
Mathew is a licensed engineer, practicing on structural projects in California, with an undergraduate degree from Cal Poly Pomona and an M.S. in Structural Engineering from UC San Diego. He has designed and managed various types of building structures, including residential wood apartment buildings, commercial steel buildings, and concrete parking structures and towers. He also hosts the new YouTube channel “Structural Engineering Life,” through which he promotes the structural engineering profession to engineering students who are not familiar with the industry perspective.
Rachel Holland, P.E.
Rachel is an experienced R&D engineer, developing and patenting multiple new structural connectors. She also offers her expertise to both the end user and specifiers as a branch engineering supervisor. She represents Simpson Strong-Tie as a deck expert, educating others how to properly build code-compliant decks. Before her career working for a manufacturing company, she spent many years working for engineering consulting companies. She earned her Architectural Engineering undergrad degree from California Polytechnic State University, San Luis Obispo, and a Master of Business Administration (MBA) from California State University, Monterey Bay. Rachel is a licensed P.E. in California, Arizona, and New Mexico.
Sources/References:
Cast Connex
University of Toronto
Severud Associates
Constructing the MSG Sphere
Constructing NASA’s Mobile Launcher 2
AISC NASCC Conference
Bechtel
Artemis Program
NCSEA
Please leave your comments or questions in the section below on how you utilize steel castings in modern construction.
