A new twist-gel spinning process for ultrahigh molecular weight polyethylene fibers is demonstrated which significantly increases the extraction rate of nonvolatile spin solvent while simultaneously reducing the consumption of extraction solvent by more than 75%. Applying twist to the gel fiber enables it to be directly hot-drawn, allowing conventional solvent extraction to proceed significantly faster. While solvent extraction effectiveness is largely enhanced, the new process does not show reduced fiber properties. The tensile strength, Young's modulus, surface morphology, and geometry are relatively unaffected when compared to fibers produced using the conventional gel-spinning process. The new twist-gel spinning process is expected to improve the processing efficiency of gel-spun high-strength fibers, promoting broad expansion of these high performance fibers into applications that were previously prohibitive due to extremely slow production. POLYM. ENG. SCI., 55:1389-1395, 2015. (c) 2015 Society of Plastics Engineers