In this work, a hybrid microwave sintering method was used to produce nanostructured and nanocomposite materials. Firstly, the hybrid microwave sintering system was designed and fabricated. Furthermore, numerical simulation of microwave-assisted hot press process was performed using Finite Element Method to examine furnace behavior in the electromagnetic field. The hybrid microwave sintering system with the maximum output power of 6 kW at the frequency of 2.45 GHz is a high power system. This machine can produce the disks with diameter of 50 mm. The bulk nanostructured Al and Al-4Wt%Al 2 O 3 nanocomposite samples were produced using the hybrid microwave sintering system to confirm the performance of the machine. Then, the samples were characterized by microstructural observations, XRD analysis, density measurement, microhardness, nanoindentation and pin-on-disk wear tests. The results showed that the nearly full-dense samples with low grain growth at sintering temperature of 550 °C exhibited good thermal stability. In addition, the hardness and elastic modulus of nanocomposite sample were increased and its coefficient of friction and wear rate were decreased. This can be due to the presence of alumina ceramic reinforcement in the nanocomposite. According to the SEM observations, the dominating wear mechanism of nanostructured Al appeared to be delamination mechanism whereas the governing wear mechanism of Al-4Wt%Al 2 O 3 nanocomposite was abrasion and delamination. Finally, a comparative study was carried out on the wear properties of Al-4Wt%Al 2 O 3 nanocomposite prepared by hybrid microwave sintering and conventional hot press sintering. The hybrid microwave sintering method showed more densification and improvement in hardness and wear resistance in comparison with conventional method. Keywords: Hybrid microwave sintering system, Hot press, Finite element simulation, Nanocomposite, Density, Microstructure