The doctoral Thesis is about the effectiveness and productivity improvement of the conventional pultrusion processes. For a better comprehension of the pultrusion process, at the beginning of the study a short review about the conventional pultrusion process, examples of numerical simulations and different approaches of optimisation is done. An effectiveness and productivity of conventional pultrusion processes, preserving the quality of pultruded profiles and reducing their cost, could be improved by the process optimization of the parameters of pultrusion process or by an application of innovative heating sources instead of electrical resistances with high heat losses. For this reason, a new effective non-linear optimisation methodology, based on experimental design and response surface technique, has been developed. An application of this methodology with two objective functions has been successfully demonstrated for the pultrusion process producing a rod profile made of glass fibre and polyester resin. The first one describes an effectiveness of pultrusion process and minimizes an electrical energy necessary for a production of pultruded profile, while the second objective function is connected with a productivity of pultrusion process and maximises the pull speed. The generalized reduced gradient algorithm has been applied for the solution of formulated optimisation problems. New technological map of pultrusion process has been developed for a designer convenience on Microsoft Excel tool, allowing to define the process conditions for the fixed process parameters and to minimize the energy consumption or to maximise the pull speed. New electro-magnetic-thermo-chemical finite element models and algorithms have been developed for a real advanced microwave assisted pultrusion process manufacturing a rod profile. To verify the results of electro-magnetic analysis obtained in finite element software ANSYS Mechanical, the finite element model for the same microwave assisted pultrusion process has been developed and analysed in COMSOL Multiphysics and no difference has been observed between both results. This talks about high reliability of the developed electro-magnetic finite element model and algorithm. At the end of the Thesis, an evaluation of the developed microwave assisted pultrusion process in comparison with the real conventional pultrusion process has been done. The obtained results have demonstrated improvement of productivity more than 5.5 times, but effectiveness – almost until 3 times. It is necessary to note that high effectiveness and productivity of microwave assisted pultrusion processes have been obtained without their optimisation. An application of optimisation could improve these values additionally.