Experimental and numerical analyses of the thermoplastic pultrusion of large structural profiles (vol 232, 112149, 2023)

•Strip thermoplastic composite profiles with cross section 75 mm × 3.5 mm were manufactured by pultrusion from glass fiber/polypropylene tapes.•A 3D heat transfer numerical model of thermoplastic pultrusion was developed to predict consolidation of tapes inside the manufacturing profiles.•Consolidation of mentioned tapes is possible at temperatures above Vicat softening temperature A50.•Heating the material to its melting point during pultrusion reduces the amount of pores present in the tapes and reduces the porosity of the profile.•Composite rectangular hollow tube of 50 mm x 40 mm x 5 mm was produced by thermoplastic pultrusion for the reinforcement of window and door frames.