This paper analyzes the casting process characteristics of Mg alloys compared with Al alloys in the production of high quality (i.e. structural) structural vehicle components. The disadvantages of traditional squeeze casting for high quality Mg components has led the authors to develop a novel squeeze casting process which overcomes the drawbacks of the current methods. The details of the new process are presented here and show the increased productivity and quality of castings that can result from changing the way molten metal is handled and processed. The feasibility of this new squeeze casting process was applied to Mg wheels for LX150 motorbikes.