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.