Bauxite residue (BR) is the hazardous waste produced during extraction of alumina by processing of bauxite ore. BR has an adverse effect on humans and the environment due to its disposable problem. To minimize the environmental impact, BR must be effectively utilized. One such way is to use BR as a reinforcing for metal matrix composite. In this study, Taguchi’s mixed fractional factorial experimentation (L18) approach is employed in the development of Al6063/BR composite through advanced stir casting process. The processparameters considered are stirring speed (rpm), reinforcement particle size (lm), reinforcement weight fraction (wt%) by weight of the matrix phase, pouring temperature (°C), and preheat temperature (°C). Later, ANOVA results indicate that particle percentage (wt%) is the major contributor in the development of porosity content. Moreover, the interaction of process parameters was also found to have an impact on porosity content. The outcome of the study reveals that the stirring intensity at 350 rpm, particle size at 80 lm, particle percentage at 2 wt%, pouring temperature at 730 °C, and preheat reinforcement temperature at 450 °C are the optimal conditions for fabricating defect free Al6063/BR composite