A well-designed coathanger die may deliver a polymer melt through the die more uniformly. However, it is difficult to optimize the manifold profile because of the complexity of flow distribution with regard to problems of die geometry, temperature, shear, and viscoelastic effects. The empirical methods have been widely used to design the manifold of a flat slit die. But this approach is time consuming and causes die material waste due to the iterative design process. With computer simulation, die designers can repeat modifications to obtain the optimal manifold shape easily. In this research, the Taguchi method was used to investigate the influences of the materials, die geometry, and processing conditions on optimizing the manifold profile. The comparison of the thickness distributions with and without modified manifold showed that the modified manifold improves the thickness uniformity significantly.