Medical device and method of manufacture yielding medical devices with consistent surface features

A medical scope comprising:

• a housing constructed of a cast aluminum alloy including Si at a maximum of 0.3% Si and at least 5% Zn;
• a micro-crystalline aluminum anodic coating on the housing of at least 0.6 mil thickness and having a uniform surface color with a maximum color difference (ΔE)of 5.0 on unadorned exterior surfaces of the housing;
• and
• a scope shaft adapted to be attached to the housing.

A product-by-process comprising a medical scope housing constructed by a process comprising:

• providing a molten casting aluminum alloy including Si at a maximum of 0.3% Si and at least 5% Zn;
• providing an investment casting mold;
• casting the aluminum alloy in the mold to create the housing and removing the mold from the housing;
• post-machining the housing to meet a desired specification;
• after post-machining the housing, performing surface finishing, , sufficient to remove impurities on casting surfaces by at least 2 mils, preferably 2 -3 mils;
• and
• coating the housing with a micro-crystalline aluminum anodic coating of at least 0.6 mil thickness.