Federer's errors combined with the extreme baseline and service power from the 2021 Miami champion Hurkacz spelled out a tough day for Federer.
Serving down 0-3 15-30 in the final set, Federer netted two consecutive crosscourt forehands to drop serve and trail 0-4.
The 24 year old Hurkacz struck several powerful serves which he paired with inside out crosscourt forehand winners in his following service game to hold serve to lead 5-0.
Then with the 6 feet one inch tall Federer serving to stay in the match, the 6 feet 5 inches tall Hurkacz sent a powerful forehand down the line for a winner.
The Pole then followed up his forehand with an equally powerful backhand down the line return winner to lead 0-30.
Federer would send a forehand as well as a backhand wide to close the match and finish with 31 unforced errors for the day.
Hurkacz for the day broke serve four times while striking 36 winners including ten aces to reach his first career grand slam semifinal which he called "super special; like a dream come true."
Federer, whose last Wimbledon crown came in 2017, underwent two right knee surgeries last year.
The quarterfinal loss was the Swiss' first ever straight sets loss at Wimbledon.
Federer also had not lost a set 6-0 since a 2008 Roland Garros loss to Rafael Nadal of Spain.