A thermoplastic pultrusion die system for pultruding a thermoplastic composite includes a first pultrusion die member with a curved, concave top surface; a second pultrusion die member with a curved, convex bottom surface; a curved die cavity gap formed between the a curved, concave top surface of the first pultrusion die member and the curved, convex bottom surface of the second pultrusion die member; a die cavity gap adjustment mechanism that imparts movement to at least one of the first pultrusion die member and the second pultrusion die member to vary the die cavity gap from closed to a specified location to open at a specified location; a pultrusion gripper mechanism having one or more grippers in series, and a computer numerical control (CNC) computer system controlling the die cavity gap adjustment mechanism.