Structural Member Formed from a Solid Lineal Profile

A method for forming a solid lineal profile, the method comprising:

• supplying a plurality of individual ribbons, wherein each ribbon contains a plurality of continuous fibers that are substantially oriented in a longitudinal direction and a resinous matrix that contains one or more thermoplastic polymers and within which the continuous fibers are embedded, the continuous fibers constituting from about 40 wt. % to about 90 wt. % of the ribbon and the thermoplastic polymers constituting from about 10 wt. % to about 60 wt. % of the ribbon;
• heating the ribbons to a temperature at or above the softening temperature of the resinous matrix;
• pulling the heated ribbons through a first die to consolidate the ribbons together and form a laminate and through a second die to shape the laminate;
• and
• cooling the shaped laminate to form the solid profile.