Several methods have been used to synthesize polymer-clay nanocomposites. In-situ polymerization with clay belongs to a classical way to develop nano-structured materials, while melt intercalation is being recognized as another useful approach due to its versatility and environmentally benign character. In this research, we prepared polymer-clay nanocomposites based on the poly (methyl methacrylate) and organically modified montmorillonite via two-stage sonication process. According to the unique mode of power ultrasonic wave, the sonication during processing led to enhanced breakup of the clay agglomerates and reduction in size of the dispersed phase. Optimum conditions to form stable exfoliated nanocomposites were studied for various compositions and conditions. It was found that a novel attempt carried out in this study yielded further improvement in the mechanical performance of the nanocomposites compared to those produced by the conventional melt mixing process, as revealed by DMA, XRD and TEM. And rheological properties of nanocomposites were measured by ARES. As a result, sonicated PMMA-clay nanocomposites exhibits enhanced properties such as storage modulus and thermal stability than that of neat PMMA.