In recent years, finite element (FE) codes have become important tools for process and product optimization for the aluminum extrusion industry. The current state-of-the-art of numerical simulations applied to the extrusion process has been presented through past editions of the International Conference on Extrusion Benchmark (ICEB) conference. By means of numerical simulation, process parameters and die designs can be optimized in order to enhance product properties and to increase productivity at a relatively low cost. When considering the defects typically encountered by extruders while producing certain types of sections, die makers can choose a die concept that helps to minimize those defects as well as further optimize the design using FEA. This first article in the series will look at how a die maker can use FEA to address geometry defects in channel profiles.