Method and apparatus for forming high strength products

A micro-layer tubular extrusion product, comprising:

• at least one micro-layer having micro-sized or nano-sized features, the at least one micro-layer formed by:
• receiving a flow of extrudable material in a non-rotating micro-layer extrusion assembly;
• constructing a series of ribbon shaped flow streams flowing parallel to a central axis of the non-rotating micro-layer extrusion assembly;
• subjecting the ribbon shaped flow streams to multiple sequences of stages while flowing parallel to the central axis, wherein, in each of the sequences of stages the flow streams are compressed, the sequences of stages further comprising:
• joining sets of the series of ribbon shaped flow streams to form multiple laminated flow streams flowing parallel to the central axis;
• dividing each of the multiple parallel laminated flow streams into at least two adjacent flow streams while compressing the resulting at least two adjacent flow streams to form thinner laminations;
• overlapping the compressed at least two adjacent flow streams side by side to each other parallel to the central axis to form an overlapped flow stream flowing parallel to the central axis, thereby multiplying the number of laminations in each of the at least two adjacent flow streams;
• repeating the dividing and overlapping steps parallel to the central axis for each of the multiple parallel laminated flow streams to multiply the number of laminations and to generate progressively thinner laminations until micro-sized or nano-sized features are obtained;
• providing an output flow stream from the multiple sequences of stages flowing parallel to the central axis, the output flow stream comprising inner and outer annular segments that are side-by-side parallel to the central axis along the length of the micro-layer tubular product;
• and
• bonding adjacent ends of the inner and outer annular segments together to form the micro-layer tubular product wherein at least one bonded end of each of the corresponding inner and outer annular segments are staggered relative to one another.