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This dissertation investigates the metal flow optimization within the deformation zone during the continuous rotary extrusion (CRE) of AZ91 magnesium alloy. The objective of this research is to enhance the material flow characteristics and improve the overall efficiency of the extrusion process. A comprehensive methodology was employed, utilizing both experimental techniques and numerical modeling. The study involved developing a robust numerical model using DEFORM® 3D software to simulate the extrusion process and understand the influence of various process parameters on metal flow. Through a series of experiments, hot extrusion exit speeds were analyzed, focusing on optimizing temperature and strain rate conditions. Results indicate significant improvements in metal flow uniformity and extrusion efficiency, leading to a more productive process with reduced material wastage. This work contributes valuable insights into the CRE of magnesium alloys and serves as a foundation for future studies aiming to optimize similar metal forming processes.