This invention relates to an aluminum conductor composite core reinforced cable (ACCC) and method of manufacture. An ACCC cable has a composite core surrounded by at least one layer of aluminum conductor. The composite core comprises a plurality of fibers from at least one fiber type in one or more matrix materials. The composite core can have a maximum operating temperature capability above 100.degree. C. or within the range of about -45.degree. C. to about 240.degree. C. or higher, at least 50% fiber to resin volume fraction, a tensile strength in the range of about 160 Ksi to about 370 Ksi, a modulus of elasticity in the range of about 7 Msi to about 37 Msi and a coefficient of thermal expansion in the range of about -0.6.times.10.sup.-6 per deg. C. to about 1.0.times.10.sup.-5 per deg. C. According to the invention, unique processing techniques such a B-Staging and/or film-coating techniques can be used to increase production rates from a few feet per minute to sixty or more feet per minute.