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This magnesium alloy AZ91D die casting is produced for a portable diagnostic machine. It is carried by technicians in the field, thus it has a requirement for ruggedness and light weight, making magnesium a natural fit. The frame measures 14" x 12" x 1" and weighs only 1.7 pounds. All keypad holes and control openings are cast in place and only deburring and paint are added operations beyond die casting. Other casting processes were considered for this component, but only die casting was chosen because of its dimensional repeatability and its ability to produce a suitable surface finish for stringent cosmetic requirements. Quantity requirements for this component are low for die casting, but again compared to other processes, the advantages of net shape die casting and its relatively low piece price allow for tooling payback to be achieved in a short timeframe.