A novel design concept of torsion screw configuration has been proposed, which allows an innovative and effective way to resolve a growing challenge in thermoplastic polymers’ ductile processibility affected by an inadequate control of mass transfer and thermal management for melts during extrusion or injection processes. More specifically, this work resolves some of the key challenges associated with plastic deformation of lightweight and porous thermoplastics and biobased polymers that are resistant to ductile deformability under high shear processing conditions. Three-dimensional numerical simulations of torsion screw have been implemented to study the influence of flow patterns of polymer melts to induce ductile formation; deformation flow patterns are compared with three typical screw geometries that are in common used in practice: the standard screw, Pin and Maddock screws. Results reveal that the torsion screw with twisted grooves provides good mixing and heat transfer ability though forced torsional diversion of particles, which avoids local overheating and subsequent breakdown of the polymer chains by inducing torsional deformation of polymers. Besides, this spiral-shaped torsional flow in a polymer channel changes the radial velocity direction, which in turn, improves interaction between velocity and temperature fields and helps to achieve good heat transfer and temperature homogeneity. The new torsion elements and their arrangement provide a novel pathway to achieve good thermal management of polymer melt by enhancing multi-field coupling. The theoretical flow model was validated with a prototype screw designed with torsional flow character.