High pressure die casting is a manufacturing process in which molten metal is injected into metal dies at a considerable pressure. Aluminium is one of the metals with excellent cast-ability. Amongst the many innovative and conventional foundry processes for Aluminium alloys, high pressure die casting is characterized by several advantages, including high yield, excellent control of operative parameters, good metallurgical and technological quality. The excellent dimensional accuracy and smooth surfaces offered by high pressure die casting process eliminates machining. Aluminium is used in 80-90% of the high pressure die casting alloys available in the world today. In many cases aluminium high pressure die casting can replace steel, increasing strength and reducing part weight. The paper is aimed at showing the potential of high pressure die casting for the production of contact carrier which is used in the electrical industry. In this paper the advantages & limitations of gravity & pressure die casting process are described. For study purpose the component is developed and tested in gravity die casting as well as pressure die casting. The test samples were subjected to radiographic, macroscopic, microstructure and hardness tests produced from both the processes. This potential is examined both in technical and economical terms, and is compared with that offered by other conventional Aluminium foundry processes, such as permanent mould gravity die-casting.