The objectives of this study were to investigate the effects of extrusion on the chemical compositions, surface structure, and molecular structure of brewer's spent grain (BSG), as well as to determine the digestible energy (DE), metabolizable energy (ME), apparent total tract digestibility (ATTD) of nutrients and energy, and amino acid (AA) digestibility of extruded BSG when fed to growing pigs. Firstly, we determined the changes in chemical compositions and molecular structure of both non-extruded and extruded BSG. In Exp. 1, eighteen growing pigs were fed three different diets including one corn-soybean meal basal diet and two experimental diets containing 20% BSG with or without extrusion. Feces and urine were collected to determine the ATTD of nutrients and energy, DE, and ME of extruded or non-extruded BSG. In Exp. 2, eighteen growing pigs were fed three different diets including 30% BSG with or without extrusion, and an N-free diet. Ileal digesta was collected through the slaughter method to determine the apparent ileal digestibility (AID) and standardized ileal digestibility (SID) of AA of extruded or non-extruded BSG. The results showed that extrusion reduced the neutral detergent fiber, hemicellulose and cellulose contents in BSG, and increased the Arg, Asp, Glu, Ser, Tyr, total indispensable AA and total AA contents of BSG, altered the surface structure of BSG, increased the peak absorbance in amide I and amide II height, amide II and amide (I+II) area, α-helix height, decreased β-sheet height, and weakened band intensities in cellulosic compounds (CELC) area, structural carbohydrates (SCHO) area, carbohydrates area (CHO) peak 2 and 3 height, the area ratio of CELC: CHO and CELC: SCHO. Moreover, DE and ME values and ATTD of energy, dry matter, crude protein, acid detergent fiber, neutral detergent fiber, cellulose and hemicellulose increased (P < 0.05) when pigs were fed extruded BSG diets. The AID and SID of Arg, His, Lys, Val and Gly increased, whereas the AID and SID of Ile and Leu decreased when pigs were fed extrusion diets (P < 0.05). Our study found that the ATTD of nutrients and AA digestibility in pigs were positively correlated with the molecular structure of proteins, and negatively correlated with the molecular structure of carbohydrates (P < 0.05). These findings suggested that extrusion had the potential to improve the nutrient digestibility of BSG by altering its chemical compositions, surface structure, and molecular structure., (© The Author(s) 2024. Published by Oxford University Press on behalf of the American Society of Animal Science. All rights reserved. For commercial re-use, please contact reprints@oup.com for reprints and translation rights for reprints. All other permissions can be obtained through our RightsLink service via the Permissions link on the article page on our site—for further information please contact journals.permissions@oup.com.)