Method for Forming Hollow Profile Non-Circular Extrusions Using Shear Assisted Processing and Extrusion (ShAPE)

A device for performing shear assisted extrusion comprising:

• a die comprising a scroll face configured to apply a rotational shearing force and an axial extrusion force to the same preselected location on the feedstock material by pushing the scroll face into the feedstock material while the scroll is rotated relative to the feedstock material to plasticize the feedstock material against the scroll face wherein a combination of the rotational shearing force and the axial extrusion force upon the same location cause a portion of the feedstock material to plasticize, the scroll face further comprising at least one groove and a portal defined within the scroll face, and
• a die bearing surface where the plasticized material is recombined, wherein the groove is configured to direct flow of plasticized feedstock material through the portal to a second location on the die bearing surface wherein the plasticized feedstock material recombines at the die bearing surface after passage through the scroll face to form an extruded material having preselected features.