The present study investigates the experimental development, characterization, and optimization of aluminum 7075 (Al 7075) metal matrix composites (MMCs) reinforced with varying proportions of fly ash. Fly ash, a lightweight industrial byproduct, was incorporated as a particulate reinforcement to enhance the mechanical and tribological properties of Al 7075. Composites were fabricated using the stir casting method, ensuring uniform distribution of fly ash particles within the matrix. The influence of fly ash content on density, hardness, tensile strength, wear resistance, and microstructural behavior was systematically analyzed. Experimental results revealed that the addition of fly ash significantly improved hardness and wear resistance, while a slight reduction in tensile strength was observed at higher reinforcement levels. Optimization of fly ash content was carried out to achieve a balance between mechanical strength and wear performance, indicating an optimum reinforcement level for superior composite performance. Microstructural analysis confirmed homogeneous particle dispersion and strong interfacial bonding between the Al 7075 matrix and fly ash particles. The findings highlight the potential of fly ash-reinforced Al 7075 composites as lightweight, cost-effective, and high- performance materials for automotive, aerospace, and structural applications.