A series of die cast AM50 magnesium test bars were made utilizing several design of experiment techniques in an attempt to determine if improved mechanical properties could be obtained. Process variables were selected and adjusted using a variables search technique during the sampling trails. Bars were tested for elongation, yield and tensile strength. Results show improved mechanical characteristics over those currently published. Findings show that temperature, pressure and gate velocity have the greatest influence on the ability of the AM50 alloy to reach the desired elongation percentages. In addition, the consistency of the high pressure die casing machine and accessory equipment had a direct effect on the success of the experiments.