In the extrusion industry, the die design process is often a trial-and-error process that involves a number of failures before reaching the required specific profile. Analysis of die failure is an important aspect of predicting the failure rate and enhancing the durability of Aluminum extrusion dies. The present study focused on the Aluminum extrusion process using semi-hollow dies of hot-work H13 steel with different shapes and sizes to determine their defect rate and percentage of failure. The extrusion speed, pressure, and friction temperatures are three major parameters in Aluminum extrusion profile defects and also in die failures. Based on the data collected from the aluminum extrusion process, analysis has revealed that Extrusion die failure can significantly impact production, product quality, and costs. Understanding the causes and effects and implementing preventive measures are essential for minimizing die failures, optimizing the production process, and ensuring consistent quality output in the extrusion industry.