Extrusion dies and methods of manufacturing the same

A method of manufacturing an extrusion die, the method comprising:

• overcoating an extrusion die with a coating material,
• wherein the extrusion die comprises a first pin comprising a first base having a first side wall and a second pin comprising a second base having a second side wall, the first pin and the second pin defining a slot therebetween,
• wherein overcoating the extrusion die comprises forming a first coating layer over the first side wall of the first pin and a second coating layer over the second side wall of the second pin, and
• wherein the first and second coating layers define a reduced slot width between the first pin and the second pin, and wherein the reduced slot width is 0% to 99% of a target slot width measured between a first exterior surface of the first coating layer and a second exterior surface of the second coating layer;
• and
• removing an overcoated portion of the first coating layer and an overcoated portion of the second coating layer from within the slot such that a cut slot width of the slot is set to the target slot width.

An extrusion die, comprising:

• a plurality of pins defining a plurality of slots arranged in a honeycomb geometry, the plurality of pins comprising a first pin and a second pin adjacent to the first pin, wherein at least one of the first pin or the second pin comprise a base comprising a non-parallel side wall with respect to a longitudinal axis of the extrusion die;
• a first coating layer disposed over a side wall of the first or second pin and comprising:
• a first exterior surface parallel to the longitudinal axis;
• and
• a second coating layer disposed over the non-parallel side wall of the first or second pin and comprising:
• a second exterior surface parallel to the longitudinal axis, and
• an interior surface opposite the second exterior surface that is not parallel to the longitudinal axis.