The variability in the mechanical properties of aluminum castings has been attributed to entrained double oxide films, commonly referred to as bifilms. These bifilms form as a result of the folding of oxide films during the handling and pouring of molten metal, causing the atmosphere to be trapped within the folded-over film. Additionally, the presence of dissolved hydrogen in the aluminum melt can exacerbate these defects, as it is expected to diffuse into the bifilm, leading to hydrogen porosity, further compromising material properties. In this study, we conducted a comparative analysis of ultimate tensile strength (UTS) and elongation percentage in sand-cast bars produced under various casting conditions. Our aim was to assess casting reliability, with a focus on the impact of oxide film content. Our findings underscore the significant improvement in tensile strength and elongation achieved by incorporating filters into the gating system and reducing the runner height. This enhancement is attributed to the improved mold filling conditions, which reduce the likelihood of oxide film entrapment. This research contributes to a deeper understanding of the factors influencing the properties of lightweight metal alloy castings and offers insights into developing practices for producing healthier castings with enhanced properties.