Squeeze casting is a process that can produce the highest quality castings. In the current study, the effect of the process settings and the in-die conditions on rejection rates is studied through a full-scale experimental study. Factors affecting the as-cast part quality were investigated in the current study from two different viewpoints. The first part of the study was to investigate the influence of the process settings on the part rejection rate, and the second was to understand the conditions in the die and the effects on the part rejection rate to understand better the reasons and sensitivity of the squeeze casting process.