<p>This study aims to manufacture high-performance carrier plates for the front of batteries that serve as key components in new energy vehicles. These types of components possess numerous threaded pillars and thin-walled features. Therefore, both internal quality and thread torque capacity need to be considered. This work used a vacuum-assisted high-pressure die-casting technology to produce the carrier plates to reduce casting defects. The impact of the casting system layout on the internal quality of carrier plates was investigated, with a focus on optimized pressure control in mold flow analysis. Based on industrial CT results, the maximum defect diameter of the optimized carrier plate was measured as 0.733 mm, and the total porosity was decreased from 8.074 to 1.31%, which met the manufacturing standards. Furthermore, the influence of microstructure at different casting positions on Vickers microhardness and mechanical properties was analyzed. More importantly, the ability of threaded holes on the carrier plates to carry torque was also evaluated through over-torque testing. The results showed that the hardness around the extruded screw thread significantly increased by about 20% compared to conventional castings due to the work-hardening effect, which helped enhance the torque capacity of the threaded holes. The optimized carrier plates with extruded M5 and M6 threaded holes could carry a maximum torque of 23.6 and 28.02 N·m, respectively.</p> Graphical Abstract <p></p>