Refining grains to the nanoscale can greatly enhance the strength of metals. But so far the fabrication routes of nanostructured metals are difficult to be applied at a large-scale industrial level owing to their high cost and size limitation. More crucially, the superior properties of nanostructured metals are easily lost during thermoforming process due to their poor microstructural stability, which limits their widespread application in engineering practice. Here we report a facile “Eutectoid element alloying→Quenching→Hot deformation” (EQD) strategy, which enables the mass production of a Ti6Al4V5Cu model alloy with α-Ti grain size of 95 ± 32 nm. In addition, rapid co-precipitation of Ti2Cu and β phases forms a “dual-phase honeycomb shell” (DPHS) structure along the grain boundaries and effectively stabilizes the nanosized α-grains. The instability temperature of the nanostructured Ti6Al4V5Cu alloy reaches 973 K (0.55Tm). The room temperature tensile strength approaches 1.52 ± 0.03 GPa, which is 60% higher than the Ti6Al4V counterpart without sacrificing its ductility. Furthermore, the tensile elongation at 923 K exceeds 1000%, more than ten times higher than the Ti6Al4V counterpart. Grain growth is not observed even under such an extreme thermal-mechanical coupling condition. This enables nanostructured Ti6Al4V5Cu to be easily shaped to complex components. The aforementioned strategy paves a new pathway to develop manufacture-friendly, high-performance metallic materials and it also has a great potential to be applied in other alloy systems.