System for manufacturing of honeycomb extrusion dies and manufacturing methods thereof

A method of modifying an extrusion die, comprising:

• mounting an extrusion die in a micro-milling machine proximate a micro-cutting tool of the micro-milling machine, the micro-cutting tool coupled to a spindle of the micro-milling machine, the extrusion die comprising a plurality of die pins, each die pin of the plurality of die pins comprising a plurality of side surfaces;
• collecting location data related to the plurality of die pins with an integrated vision system of the micro-milling machine, the location data comprising at least one of angle, orientation, or length of each side surface of each die pin of the plurality of die pins;
• generating a die pin location map from the location data;
• using the die pin location map to generate a numerical control file defining a cutting path for the micro-cutting tool of the micro-milling machine;
• and
• removing material from one or more die pins of the plurality of die pins using the micro-cutting tool, the micro-cutting tool making one or more cutting passes against the side surfaces of the one or more die pins to remove the material individually and independently from the one or more die pins one die pin at a time.