Abstract: This paper aims to address the challenges of cracks, shrinkage defects, and dimensional accuracy in the casting process of turbocharger impellers. Through a closed-loop research framework integrating "structure-process-performance-application," the study combines theoretical modeling, experimental testing, and industry requirements. It reveals the initiation mechanisms of cracks at the blade root and shrinkage cavities in the hub; establishes a high-precision casting process system tailored to impeller structural characteristics; and achieves a reduction in manufacturing defect rates from 40% to below 3%, with qualification rates exceeding 95%, while ensuring the process is suitable for mass production.