This study was implemented to investigate the effect of hot press forging process on different chip size (S), pre-compaction cycle (PCC), and holding time (t) in direct recycling of aluminum alloy AA6061. The mechanical properties of recycled chips were determined by measuring the ultimate tensile strength (UTS) while physical properties were studied by examining the microstructure, and recycled chips were compared with the original AA6061 aluminium billet. The experimental result indicates that hot pressed AA6061 aluminium alloy using larger S, maximum cycles of PCC, and maximum t, gave the optimum value of UTS at 122.33 MPa and 120.45 MPa respectively. It was found that larger S used with higher number of PPC and longer the t will produce better mechanical and physical properties of the recycled AA6061 chip.