Abstract: The continuous fiber reinforced thermoplastic resin samples were prepared by pultrusion with glass fiber/polypropylene composite yarn as raw material. The pultruded samples were obtained on the lab-designed thermoplastic pultrusion line. The influences of the threading way of composite yarn, die structure, die temperature and pultrusion rate on the properties of the samples were investigated, so was the morphology of the cross section. The results showed that by adopting convergent cavity structure, increasing mold temperature and reducing pultrusion rate, the combination between glass fiber and resin was improved, the uniform distribution of fiber in the product was promoted, the porosity decreased and the mechanical properties were improved.