Thermal performance of nanofluids is intensely influenced by the traits of nanoparticles and external factors affecting the working fluid. These interactions have a key role in determining the effective heat transfer features, offering thorough analysis of the underlying thermal mechanisms. Understanding of these influences is essential for accurately illustrating the heat transmission process in nanofluids. One of these factors is the nanoparticle aggregation effect. Considered study examines the flow of a nanofluid \(\:\left(Ti{O}_{2}/EG\right)\) across an extended surface, driven by significant convection, while considering the effects of nanoparticle clustering and thermal radiations. The foremost objective of this research is to analyze the flow of magnetohydrodynamic radiative nanofluid within a porous media across a stretching surface while considering thermal radiation, nanoparticles aggregation and a nonuniform heat source. The Darcy model is used to simulate porous medium. Moreover, the base fluid is ethylene glycol and the nanoparticle like titanium oxide considerably increases the fluid’s heat transmission capabilities. This work scrutinizes the thermal and flow dynamics of a boundary layer system, where the governing partial differential equations are reduced to a coupled system of ordinary differential equations via a non-dimensional similarity transformation. Numerical solutions developed employing MATLAB’s bvp4c solver reveal the intricate influence of physical parameters such as porosity, magnetic field intensity, Prandtl number, thermal radiation, and Biot number on velocity and temperature profiles. Results demonstrate that increasing magnetic and porosity parameters suppress the velocity field, whereas upsurge in the estimates of thermal radiation, and Biot number significantly enhance the thermal profile. Considered study uniquely integrates nanoparticle aggregation effects into viscosity and thermal conductivity models while simultaneously employing a nonlinear radiation model with non-uniform heat generation/absorption, offering a comprehensive and rarely addressed framework for thermal transport analysis. The proposed study can contribute to improved heat dissipation in high-performance components, enhance cooling strategies in propulsion and electronic systems, and increase energy efficiency in materials processing applications.