Three innovative extrusion processes are presented: Extrusion of profiles with variable shapes, 3D curved profile extrusion for the manufacture of profiles with complex contours, and helical profile extrusion for the manufacture of twisted profiles. All these processes are based on influencing the material flow inside and behind the extrusion die. These procedures profit from the fact that only a very low load is needed to deflect the material flow in order to produce complex variable geometries. The results of experimental as well as numerical investigations are presented. The process limits and examples of extruded parts are also shown. © 2012 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim.