Long-fiber pellets were made by an in situ pultrusion process. Fiber-reinforced composites were prepared by an injection-molding process and an extrusion/injection-molding method with pellets, respectively. SEM observations showed that the strong interface was maintained during the injection process for low shearing forces, although polymer adhesion to the fiber surface was completely delaminated in the process of extrusion/injection molding for very high shearing forces. Enhanced adhesion of composites promoted substantial improvement of mechanical properties compared to those with poor adhesion. However, the enhanced adhesion between the fiber and the matrix also sacrificed the impact resistance properties. Longer fibers substantially enhanced the properties of composites. (C) 2004 Wiley Periodicals, Inc.