HSS Insider – May 2026 – 3D Printing

May 2026 | Issue #44

This HSS Insider issue explores how additive manufacturing is creating new opportunities for tubular steel construction and complex HSS connections. You’ll also find the new HSS Market Availability Guide, details on the returning 2026 Mastering HSS Connections webinar series and upcoming free June webinar, plus registration information for the 2026 HSS Summit in Huntsville, Alabama.

Additive Manufacturing for Tubular Structures

Wire arc additive manufacturing (WAAM) is creating new opportunities for tubular steel construction, particularly for complex HSS connections and custom structural components. This article examines where WAAM fits alongside traditional fabrication and steel castings, as well as with the material properties, fabrication considerations, and emerging design standards shaping its future in the construction industry.

---

HSS Market Availability Guide

The HSS Market Availability Guide provides a clear snapshot of current production capabilities from all STI HSS producers, representing a majority of the market. This guide not only indicates current availability but also which sizes are regularly produced versus produced on demand. Use it to align your designs with efficient material sourcing across ASTM A500, A1085, and A1065 specifications.

---

Webinar

The Mastering HSS Connections Series

STI is continuing the Mastering HSS Connections webinar series in 2026 with a comprehensive, multi-session program focused on HSS connection design. Building on the 2025 series launch, this series combines live and on-demand learning to give you the tools and confidence to design a wide range of connections.

From fundamental principles to more advanced design topics, each session is built to help you take on real-world challenges.

Earn Continuing Education Credits – Earn up to 12 PDH credits, with 1 PDH available per webinar. 

Click below for series packages and pricing. Receive discounts as an HSS Professional Member. Click here to become an HSS Professional Membership.

---

Free Webinar | One Sided Bolting – No “ifs”, “ands” or “Nuts”!

Take a closer look at one-sided bolting options for HSS connections as alternatives to welding and through-bolting, with discussion on connection behavior, load transfer, and detailing considerations. This June webinar also examines applicable design references and key limit states to check in the supporting HSS wall that often governs connection capacity. Participants can earn 1.0 PDH upon completion.

This live webinar has already been presented. Click below to watch other HSS recorded webinars on demand.

---

2026 HSS Summit
Registration is Open

The Steel Tube Institute’s 2026 HSS Summit brings together fabricators, service centers, and engineers November 10–12 in Huntsville, Alabama. This exclusive 2.5-day event features expert-led educational sessions and collaborative discussions focused on the latest opportunities, challenges, and innovations in Hollow Structural Sections (HSS).

Attendees can also take part in guided tours of the Nucor Steel Decatur hot roll mill and Nucor Tubular Products facility, plus enjoy a special reception and dinner at the U.S. Space & Rocket Center beneath the Saturn V Apollo moon rocket.

• Continuing Education: Learn about material availability, connection detailing, design and fabrication, software, manufacturing equipment, and sustainability. Sessions are eligible for PDH credits.
• Roundtable & Panel Discussions: Exchange ideas and best practices with industry leaders and peers.
• Breakout Sessions: Participate in targeted discussions tailored to your role and interests in the industry.

Register now to receive the launch pricing of $200 (available through June 30).

---

Related Resources

Connecting to Structural Castings

This article provides practical insights to effectively connect structural connections, including fabrication methods, performance benefits and design advantages, to help engineers make more informed decisions. Learn how to leverage structural castings for stronger, more efficient applications.

---

The Capabilities, Value and Opportunity of Designing With Steel Castings

Steel castings offer a unique combination of strength, flexibility, and design efficiency that can unlock new possibilities across a wide range of applications. In this interview, Carlos de Oliveira, Cast Connex, shares his insights on how engineers and designers can leverage these advantages to improve performance while optimizing cost and production. It’s a practical look at where steel castings are creating real value today, and where the biggest opportunities lie ahead.

---

HSS: Your Questions, Answered

Q: What is the market availability of round HSS versus pipe?

A: Generally, round HSS sections that correspond to common pipe sizes are the most readily available in the market. Many of the round HSS shapes that are readily available are those whose O.D. (outside diameter) matches the I.D. (inside diameter) of common pipe sections.  The STI Article: Selecting the Right Round HSS provides a handy table of these equivalent shapes.  It is recommended to specify round HSS A500 Grade C, not pipe ASTM A53, per this STI Article: A500 Versus A53: Different From the Inside Out.

To view current sizes and which producers manufacture a specific round HSS section, refer to the STI Capability Tool.

---

Sustainability Contest Winner

Congratulations to D. Wynne, with Meier Architecture • Engineering, the winner of a $150 Amazon gift card from our Sustainability Contest! Keep an eye out for a chance to win in our next HSS contest.

---