Purpose The purpose of the study is to explore the three-dimensional heat and mass transport dynamics of the magneto-hydrodynamic non-Newtonian (Casson fluid) hybrid nanofluid flow comprised of − as nanoparticles suspended in base liquid water as it passes through a flexible spinning disc. The influence of a magnetic field, rotation parameter, porosity, Darcy−Forchheimer, Arrhenius’s activation energy, chemical reaction, Schmidt number and nanoparticle shape effects are substantial physical features of the investigation. Furthermore, the influence of hybrid nanofluid on Brownian motion and thermophoresis features has been represented using the Buongiorno model. The novelty of the work is intended to contribute to a better understanding of Casson non-Newtonian fluid boundary layer flow. Design/methodology/approach The governing mathematical equations that explain the flow and heat and mass transport phenomena for fluid domains include the Navier−Stokes equation, the thermal energy equation and the solutal concentration equations. The governing equations are expressed as partial differential equations, which are then converted into a suitable set of non-linear ordinary differential equations by using the necessary similarity variables. The ordinary differential equations are computed by combining the shooting operation with the three-stage Lobatto BVP4c technique. Findings Graphs and tables are used in the process of analysing the characteristics of velocity distributions, temperature profiles and solutal curves at varying values of the parameters, along with friction drag, heat transfer rate and Sherwood number. It has been revealed that the radial and axial velocities decrease when the Casson parameter value increases and that the rate of heat transmission is higher in hybrid nanofluids with nanoparticles in the shape of a blade. The increase in Brownian motion and thermophoresis parameters causes a rise in the temperature profile. Also, an increase in the activation energy parameter improves the solutal curve. The use of nanoparticles was shown to improve extrusion properties, the rotary heat process and biofuel generation. Originality/value All results are presented graphically and all physical quantities are computed and tabulated. The current results are compared to previous investigations and found to agree significantly with them.