Structural member

A system and method of manufacture providing reinforced structurally functional load-bearing members, including but not limited to using thermoplastic materials, such as High Density Polyethylene (HDPE) or polypropylene (PP), reinforced such as with an aluminum alloy, glass-reinforced polyurethane (foamed or unfoamed), or carbon fiber core element. Among its possible uses, the present invention has application for provision of structural support members, such as an illustrative I-joist product having a vertical center member preferably comprising a thermoplastic material, and top and bottom flanges having structurally meaningful reinforcement. The center member and flanges preferably comprising a thermoplastic material provides a relatively hard, durable, substantially weather-resistant structure. Certain embodiments of the present invention include reinforcing members having a plurality of lobes or arms. Additional embodiments include indentations along the reinforcing members, such as the arms, to aid in bonding between the thermoplastic outer material and reinforcing member within the thermoplastic material. Certain embodiments of the present invention include reinforcing members used in combination with a foamed area and a thermoplastic material.