Episode 128 - Casting the Impossible: Rethinking Steel Connections

The Structural Engineering Podcast · Oct 7, 2026 · 1h 4m

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…