Extrusion dies with smooth entry from a circular cross-section into an extruded shape are used in the extrusion of steels, superalloys, and titanium alloys. A significant application for smooth entry, or “streamlined”, extrusion dies is found in the extrusion of preforms for forging titanium turbine and compressor blades. In this application, before forging the thin airfoil section, a round- or preferably elliptical-shaped preform is extruded from round bar stock. The shape of the preform and the surface of transition from the round to the elliptical cross-section influence the subsequent defect-free forging of the blade. The difficulties of designing and manufacturing the complex dies and of maintaining consistent lubrication have somewhat inhibited a wide application of the lubricated-extrusion process in the production of non-symmetric shapes. An example is the hot extrusion of high-strength aluminum alloys, 2000 and 7000 series. The conventional practice is to extrude structural shapes of these alloys using flat-face dies. This practice results in internal shearing and significant temperature increases within the deforming material. Consequently, the extrusion must be carried at a sufficiently low speed to avoid hot shortness in the product. Lubricated extrusion of hard aluminum alloys can be expected to increase production rates and lower the required press capacity to extrude a given product at a predetermined extrusion ratio. This paper discusses new techniques for the design and manufacture of dies for lubricated extrusion of non-circular shapes. A simple analysis of the direct-extrusion process is developed and used to formulate a design procedure for determining the optimal shape of the extrusion dies. To manufacture the complex dies by NC (Numerical Control) machining and EDM (Electro-Discharge Machining), special computer programs have been written. The design procedure and the NC programs are applicable to cold and warm, as well as to lubricated hot extrusion of non-circular shapes. In this study, dies were designed and manufactured for lubricated hot extrusion of round and rectangular shapes. The results of extrusion trials conducted with these dies indicate that these new die-design techniques can be useful in some extrusion applications.