This research focuses on the development and characterization of stir casting process parameters for Al6061–SiC Response Surface Methodology in metal matrix composites (RSM). Aluminum 6061 serves as the matrix material, while silicon carbide (SiC) particles (size < 10 µm) are used as reinforcement. AMMCs, or aluminum metal matrix composites, were created via the method of stir casting, a cost-effective and efficient technique. The composite specimens were prepared following the RSM Box–Behnken design, with optimization performed using the Desirability Function. The key process parameters investigated include reinforcement weight percentage (3.5, 7.0, and 10.5 wt%), melting temperature (625, 650, and 675 °C), and stirring speed (225, 250, and 275 rpm). Mechanical attributes such as impact strength, tensile strength, and hardness were assessed. The results indicated that these properties improved with increasing silicon carbide content in the aluminum 6061 alloy. From the microstructural analysis using a metallurgical microscope and high-resolution scanning electron microscope (SEM), it can be concluded that the SiC particles are fairly evenly distributed within the aluminum matrix, with minor occurrences of particle clustering and porosity.