Extrusion die and method of forming

A method of making a die for extruding honeycomb structures with hexagonal cells which comprises:

• forming a plurality of spaced-apart hexagonal pins on a plurality of support means by cross-cutting each support means with sets of parallel grooves across a surface portion of the support means such that each set intersects another set at an angle of 60 degrees to form the hexagonal pins therebetween, bonding the pins of an individual support means to a die member surface and removing the support member from the bonded pins, positioning and bonding the pins from the plurality of support means to the die member surface in the same manner as the individual support means until hexagonal slots are formed on the die member surface between the bonded hexagonal pins, and providing feed holes in the die member to communicate with the hexagonal slots.

A method of forming a discharge face portion of an extrusion die which comprises:

• forming a plurality of spaced-apart hexagonal-shaped pins on at least three initial members by cutting a plurality of parallel grooves in a given direction across a surface portion of each initial member to form two sides of the hexagonal pins, thereafter cutting a second set of parallel grooves at an angle of 60 degrees with respect to the initial given direction across a surface portion of each member to form two additional sides of the hexagonal pins, thereafter cutting a third set of parallel grooves at an angle of 120 degrees with respect to the initial given direction across a surface portion of each member to form the final two sides of the hexagonal pins, and sequentially bonding the hexagonal-shaped pins from each of said initial members to a master member to form hexagonal discharge slots therebetween.