High-pressure-Die-Casting (HPDC) is an efficient manufacturing method in which molten metal is poured into a permanent mould and solidified under high pressure, as defined by standard EN 1706. The resulting high-speed injection allows high productivity and high cooling rates resulting in fine microstructure. The combination of quick metal filling, low cycle-times and multi-variables die control makes HPDC a “defect-generating process” in which process parameters are difficult to maintain constant. HPDC aluminium alloys for automotive structural components (Emin = 10%, YSmin = 120 MPa) are typically Al-Si systems with very low tolerances of detrimental alloying elements as Fe, Cu, Zn, which can be generated during the recycling process. For this reason, high scrap rate secondary alloys are not used for structural components because of brittle intermetallics and reduced castability. In this study, casting trials with secondary (90% end-use scrap) AlSi10MnMg alloy were performed for assessing the injection curve and casting parameters (melt temperature and treatment, injection speed and change position, etc.) and the effect of the compositional variations on the quality of the castings produced. A 5250-kN locking force cold chamber HPDC machine with a die designed for fabricating a 130x170 mm flat plate with 3 mm thickness was used. A ProVac Ultra Easy 2000 valve and a ProVac CV 300 chill vent were employed to achieve a residual pressure of 100 mbar in the die. A total of 850 specimens were produced and evaluated according to surface quality per-visual inspection in comparison with HPDC machine data. Visual quality parameters used were the presence of filling and superficial solidification defects, blisters, water marks and defect-free appearance. After the data analysis of the grades (1 to 5) and the relative averages, the optimal set of parameters was selected and further 150 specimens for each alloy variant are casted for mechanical and functional characterization. This study aims at contributing to the European efforts for the transition towards more sustainable raw materials usage and the ongoing research on secondary aluminium alloys for automotive structural components. The present study is framed in the EU-funded project SALEMA.