The optimization of process parameters is necessary, as it increases the utility not only for machining economics but also for the reduction in production time and cost to a great extent. This research has been undertaken with a main objective to overcome the problems during fabrication, characterization, and machining of Al6061-Cu-SiCp composites. The research work has been focused on the following aspects:Fabrication of Al6061-Cu-SiCp (particle size 16 μm) composites with maximum homogeneity in dispersion of silicon carbide particulates.Microstructural examination by scanning electron microscope to study the proper distribution of grains.Carrying out tests to find out mechanical properties like impact strength and hardness.Machining performance evaluation of Al6061-Cu-SiCp composites as well as comparative examination of Al6061-Cu matrix alloy at different levels of process parameters (production). It is justified that composites are better than a matrix alloy of the same metal in terms of machining ability and mechanical properties. Analyzing the effect of manufacturing/process parameters (pouring speed, stirring speed, and pouring temperatures) on the material removal rate (i.e., machining ability) through electrical discharge machining.Statistical analysis and significance of observed data calculated through analysis of variance technique (ANOVA) and Statistical Package for the Social Sciences (SPSS) software.For generalizing the result, linear regression analysis was done.