A method of designing a die cavity can include performing a flow analysis using characteristics of a predetermined die cavity design, density and rheological properties of a material to be extruded, and a flow rate of the material to calculate the pressure distribution exerted on the die cavity and cross-sectional flow profile. The method further includes performing a structural analysis using the calculated pressure distribution and structural characteristics of the die cavity to calculate a deformed die cavity. The flow analysis is then repeated using the characteristics of the deformed die cavity to calculate a pressure distribution exerted on the die cavity and cross-sectional flow profile. The calculated pressure distributions and/or cross-sectional flow profiles are compared to determine if the pressure distributions and/or cross-sectional flow profiles converge. These steps are iteratively repeated until convergence of the pressure and/or cross-sectional flow profile is observed. Once convergence is observed, the variation of the cross-sectional flow profile is analyzed to determine if it is less than a predetermined tolerance.
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