Cast AZ91 and extruded AM50 alloys were isothermally heated as solid/liquid coexistent temperatures, and semi-solid formed into sheets. Mold filling ability of semi-solid slurry with different liquid fractions was investigated in relation to process variables such as injection speed and mold temperature. Relatively uniform distribution of solid particle size and liquid fraction were observed throughout the semi-solid formed sheet. AZ91 alloy sheets were also manufactured by conventional die casting and compared with the semi-solid formed. It was found that the surface was more smooth and the dimensional accuracy was higher in case of the semi-solid formed.