A method of forming a thermoplastic vulcanizate by first providing a melt-blender having a die through which melt-blended thermoplastic vulcanizate passes to form a shaped article; wherein the die comprises a flow design having at least one flow branch having a taper angle and a flow reservoir at the end of each flow branch; and wherein the taper angle of the flow design ranges from 5 to 20 degrees; followed by melt-blending a thermoplastic and an elastomer with an organic peroxide curative in the melt-blender to form a thermoplastic vulcanizate; and finally, passing the melt-blended thermoplastic vulcanizate through the flow design to form the shaped article.