A experimental research has shown that MLFM-mulitple live feed process control parameters can be optimized to develop defect free powder injection molded aluminum matrix composites (AMC) with 20 mm in thickness. The focus was on developing PIM AMC test bars from a range of mixes using conventional and MLFM machines. The study prepared composite mixes (MC) using a co-rating twin-screw extruder, performed rheological study and experimentally molded the composite mixes them that led to the identification of the suitable mix containing 65 v/o aluminum powder. Low viscosity composite mix MC-1 developed flow lines in the bars while MC-2 had an acceptable viscosity for operating the MLFM device and parts were produced without flow lines, and micovoids. Blisters in molded bars were controlled by reducing the die cavity temperature where high die temperature resulted in degradation of the low temperature constituent in binder.