The study investigates the radiation effects on the flow behavior of an electrically conductive Casson fluid in the presence of a magnetic field, coupled with a chemical process. The analysis considers velocity slip phenomena over an inclined non-linear stretching surface within a Forchheimer permeable medium. The governing partial differential equations are transformed into nonlinear ordinary differential equations using appropriate similarity transformations. These equations are then solved using the Runge–Kutta-fourth method and shooting methodology in MATLAB. Graphical representations of flow, temperature, and mass concentration are generated for various values of parameters such as magnetic quantity (
), Casson fluid quantity (
), Prandtl number (
), Schmidt number (
), chemical reaction parameter (
), Forchheimer parameter (
), and permeability parameter (
). Additionally, the study employs Response Surface Methodology (RSM) to analyze the influence of parameters like Casson fluid quantity (
), inclined magnetic field (
), and Forchheimer parameter (
) on the skin friction parameter (
). The RSM technique, utilizing a second-order polynomial regression model, optimizes Cf around its peak, demonstrating the significance of main effects and their interactions. The numerical results indicate a significant decrease in flow velocity with increasing magnetic parameter. The statistical analysis reveals that main effects are significant at a 5% level of significance, with a high coefficient of determination (
) of 99.98%. Notably, 92% of
is attributed to main effects, emphasizing their relevance and superiority in influencing
.