This thesis focuses on the analysis of process factors that influence the formation of defects in aluminium alloy components produced with the high pressure die casting process, with specific application in the automotive sector. The main objective is to understand which variables have the greatest impact on production scraps rate, in order to optimise the process, improve casting quality and reduce the costs associated with the production of defective parts. The industrial context of this work is characterised by an increasing need for efficiency, repeatability and quality in the production of complex structural components. Die casting, although a well-established process, presents numerous challenges related to defect control, which may manifest as porosity, cracks or surface defects.