This paper presents the results of research that is being carried out within the EU-funded MedCast Project entitled “Development of Foundry Casting Methods for Cost-Effective Manufacture of Medical Implants” (MedCast). The partnership is led by DePuy Johnson & Johnson with two university collaborators.

Research has focused on understanding the behaviour of stucco application methods on the performance of investment casting shells. Weibull statistics were adopted to develop a robust testing method for the mechanical strength of the shells. Statistical methods were used to understand the main influences of stucco application on both prime and back up layers of the shell system. The flexural strength, permeability, edge strength and overall weight of the samples were analysed using this approach. The microstructural changes were also analysed as part of this study.