The paper presents two new innovative direct extrusion process variants, Twisted Profile Extrusion (TPE) and Helical Profile Extrusion (HPE), which increase the flexibility of aluminum profile manufacturing processes. The investigations concentrate on experimental and numerical analyses by 3D-FEM-simulations to analyze the influence of friction on the material flow in the extrusion die in order to find out the optimal parameters with reference to the twisting angle and contour accuracy to manufacture twisted and helical profiles by extrusion. For these investigations a common aluminum alloy EN-AW6060, was used. In the experimental investigations, different coating technologies and, in the simulations, various friction values and die design concepts are analyzed to be able to influence and optimize the material flow when exiting the die.