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In the present research work experimental investigations has been made for development of Al- Al2O3 MMC (metal matrix composite) by combining stir casting and ABS (acrylonitrile butadiene styrene) replica based investment casting. The research started with selection of the standard geometrical component (cube for the present study).The research highlights the effect of reinforcement Al2O3 on mechanical and metallurgical properties of Al based MMC. The input parameters of process are material composition, layer combination and pouring temperature in investment casting. The study highlights the percentage contribution of different input parameters on micro hardness and dimensional accuracy of Al- Al2O3 MMC.