This study compared the surface roughness of composites with 10% nano kaolinite and manufactured them with a novel encapsulation technique to the ascast AA5059. Utilizing a novel encapsulation technique, the stir-casting process was employed to create samples for both groups. For group 1, AA5059 was used as cast, while for group 2, a composite comprised of nano kaolinite (10%) and AA5059 was used. The samples were made following ASTM E92 specifications, and the surface roughness was assessed using a Mitutoyo surface roughness tester (SJ-410). Each group contained 20 samples. The sample size calculation was performed using a G-power of 80%, α per set = 0.05, and a total sample size of 40. The material containing 10% nano kaolinite filler exhibits the highest surface finish, which is 39% lesser than AA5059 in its as-cast state. The statistical t-test research demonstrates that there could be a significant p = 0.00 (p < 0.05) difference between group 1 and group 2’s mean variance of surface finish. Within the limitations of this study, it is manifest that the 10% nano kaolinite reinforcement significantly reduces the AA5059 composite’s surface roughness.

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