Coventional pultrusion of thermoset composites is under increasing examination for emissions of harmful volatiles from the resin wetout tank. Even though the pultrusion of thermoplastic matrix composites produces no emissions, it is difficult to wet individual fibers due to their high melt viscosities. This paper addresses both the issues of volatiles and wetting with a process called Reaction Injection Pultrusion (RIP). A prototype RIP machine was used to make both thermoplastic polyurethane and thermoset polyisocyanurate matrix composites. The RIP process produces pultruded parts with low void content, good surface finish, and acceptable mechanical properties. The low viscosity constituents used in RIP help improve fiber impregnation, while the small volume of the impregnation bath reduces emissions. Processing parameters such as line speeds, catalyst levels, and die temperaures were varied to establish processing guidelines for sustained production.