Recent studies have demonstrated that highly multilayered blend morphologies can be formed by chaotic mixing and captured within extrusions of various forms. The number and thickness of internal layers prior to layer breakup and the extent of breakup are controllable via specification of process variables. A variety of derivative morphologies can thereby be obtained. Although methods can be applicable to other blends, the relation of oxygen permeability to various morphologies was specifically investigated in this study for extruded films without drawing consisting of ethylene vinyl alcohol copolymer, low density polyethylene and maleic anhydride modified polyethylene as a compatibilizing agent. Optimal barrier properties were obtained in a novel single phase continuous and mechanically interlocked morphology that was an outcome of stretching and folding characterizing chaotic mixing. Barrier properties were similar to those obtainable in co-extruded films because of the presence of abundant platelets across the film thickness and crystallinity increases caused by barrier phase refinement.