A notebook computer component with a complex geometry was manufactured with a die cast process (DCP), using an AZ91D alloy. Chemical conversion and organic coatings were sequentially applied to provide protection against physical and chemical damage. Air content in the component, which gives rise to microporosity, was determined with a DCP computer simulation using MAGMA software. The surface layer characteristics of the component were also investigated using scanning electron microscopy coupled with energy dispersive X-ray spectroscopy. The microporosity content was higher at the end of the filling process compared with the regions that filled first. Corrosion resistance was poorer for discontinuous conversion coatings that resulted from surface microporosity. Moreover, adhesion of an organic coating was degraded at areas with higher microporosity.