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, GA number 251269). The partnership is lead by DePuy Johnson & Johnson with three university collaborators.

Research has focused on understanding the behaviour of a rapid drying shell system. The chemistry and behaviur of super absorbent polymers are examined. The strength, permeability, thermal expansion and microstructure of a rapid shell system are compared to a representative shell system with drying times that reflect current industry practice. The efficacy of using the system within a production environment is also analysed. The large thermal gradients during firing and push for even shorter lead times results in new challenges for a rapid shell system which are presented and investigated within this paper.