Abstract: In order to realize the potential of composite materials, it is imperative to develop a manufacturing process, to understand the microstructures, and to assess the structural performance of the composite. The braided-pultrusion process, which combines the pultrusion process with the braiding technology, has been developed by utilizing a novel resin impregnation device. The goal of the development is to achieve both costeffectiveness and performance of the composite. The tubular composites of diameter 5.3 mm have been produced using Kevlar 49 fiber and polyester resin. In order to assess the mechanical performance of the composites, an analytical method for predicting the elastic constants has been developed. The analysis includes the geometric model of a unit cell, coordinate transformation, and averaging of stiffness and compliance constants of the constituent materials. The analytic predictions compared favorably with experimental results.

Key words: braided pultrusion, impregnation, structural performance