Chaotic systems are vital in designing contemporary cryptographic systems. This study proposes an innovative method for constructing an effective substitution box using a 3-dimensional chaotic map. Moreover, bouyed by the efficiency of the proposed chaos-based substitution boxes’ effectiveness, we introduce a new chaos-based image cryptosystem that combines the adeptness of Gray codes, a non-linear and sensitive hyper-chaotic system, and the proposed S-box. The generated secret key emanating from the cryptosystem is correlated to the input image to produce a unique key for each image. Extensive experimental outcomes demonstrate the utility, effectiveness, and high performance of the resulting cryptosystem.