The thermoset pultrusion generally consists of two steps: Resin infiltration into the dry reinforcement and Resin Cure. These two steps are carried in sequence and are coupled by the material motion. In the first step the dry reinforcement is impregnated with resin as it passes through a pressurized resin infusion chamber. Then, the reinforcement is compacted as it is pulled through a die which compacts the reinforcement increasing the fiber volume fraction and may complete the resin saturation due to the buildup of the pressure in the die. In the second step, the saturated tape moves into a heated die and resin cures before it exits the tool. The coupling between two stages is usually limited by the same material velocity, as the heated die tends to be thermally insulated from the infusion chamber. However, the common processing speed constitutes serious constraint to process optimization. A process model is developed which is incorporated in an existing numerical simulation of resin infusion that can predict the relevant changes of the state in the dry fiber reinforcement tape as it passes through the tooling set, first during the infusion stage, then during the cure for complicated profiles. The simulation is used to identify a process window for the range of parameters for successful manufacturing without voids or dry spots. In addition one can use the virtual manufacturing simulation to optimize the entire process. The model considers the infusion dynamic in the pressurized chamber and relates the tape velocity with pressure, resin viscosity and reinforcement layup. For the cure stage, the limits are dictated in relation to prescribed velocity and applied heating. Experiments are also conducted to validate the cure and temperature profile during the process.