Process for continuous fabrication of highly aligned polymer films. A polymer-solvent solution is subjected to a high shear, high temperature, Couette flow to extrude a thin film having polymer chain disentanglement. The extruded thin film is frozen and the solvent is allowed to evaporate to form a dried film. The dried film is mechanically drawn using a constant force, adaptive-thickness drawing system to align polymer molecular chains through plastic deformation. A suitable polymer is ultra-high molecular weight polyethylene.