Lightweight design and manufacture of die casting magnesium alloy seat frame

• A novel structure was designed that integrates the headrest with the backrest, combining lightness and safety. • Development of a new forward production logic for Mg seat castings. • Actual production cases inspire OEMs to develop Mg castings. • Forming simulations, production, and experiments validate Mg alloy die casting seat performance. • Enhanced the reputation of domestic car brands and demonstrated the potential for mass production of Mg alloy die casting parts. This study presents the development of a Magnesium Alloy Seat Frame (MASF), supported by case studies from automotive original equipment manufacturers. The process covers integrated design, simulation, manufacturing, and testing, aiming to boost industry confidence in Mg alloy applications. A novel structural design is developed that integrates the headrest with the backrest, achieving a balance between lightweight performance and safety. Structural optimization is guided by stress–strain simulations under diverse conditions within a complete forward development process. Casting simulations are conducted to analyze process characteristics, resulting in a verified MASF yield rate exceeding 90 %. The final 9.88 kg MASF represents a 24.6 % (3.23 kg) weight reduction versus a steel seat. This research contributes to advancements in defect control technology for large die casting magnesium alloy parts and has broad implications for their application in automotive manufacturing.