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High level vacuum die casting (HLVD) allows the casting products heat treatable with aid of minimized gas contents (e.g. max 1cc/100gAl), therefore it shows improved mechanical properties. In order to decrease the gas content of castings, vacuum level in cavity should be maintained under 5kPa during mold filling process. For the quality control of mass production, the practical inspection system should be required in the production process. In this study, we have focused on finding the relationship between process parameters and gas porosity, one of the main casting defects. We developed thin walled bracket with HLVD process to achieve weight reduction as well as cost saving. In addition, improved mechanical properties and productivity were acquired.