In the present work new replication techniques for a biomedical component having a real 3D shape has been introduced. A dynamic condylar screw (DCS) plate was selected as one of a real 3D biomedical implant for this study. The DCS plate, made of ABS material, was fabricated as a master pattern by fused deposition modelling (FDM) method. After preparation of master pattern mould was fabricated with vacuum moulding process. Finally metal matrix composite (MMC) of Al and Al2O3 has been prepared in vacuum mould for fabrication of DCS plate. This study highlights the replication procedure of DCS plate in detail from the master pattern to a final product with some investigation on mechanical and metallurgical properties.