Plastics extrusion is a highly cost-effective high-volume manufacturing process with wide-ranging industrial applications. To achieve a high-quality product, it is absolutely essential to have properly designed extrusion dies in order to obtain the correct velocity profile and temperature distribution during extrusion. This article describes an integrated application of CAD/CAM and finite element analysis to assist with the design of the multistage die for profile extrusion. Techniques for economic manufacture of the extrusion die by wire-cut EDM are also fully discussed.