The die is considered as a crucial component in the aluminium extrusion process. Maintaining die integrity is key to the efficiency of the extrusion process, guaranteeing high product quality and uninterrupted operations. Within this specific context, the investigation of crack initiation growth extrusion die is being conducted. Initially, numerical analysis was carried out and validated based on experimental investigation of extrusion die crack location and orientation. Afterward, a numerical investigation was undertaken on the die crack propagation. The analysis was performed using the extended finite element method (XFEM). The results led to an enhanced comprehension and prediction of the spread of cracks in the extrusion die. The findings provided improved understanding and prediction of the propagation of multiple cracks in several locations in the die. By computing the die crack propagation, we seek towards a more robust and scientifically analysis methodology for extrusion die design optimization.