Abstract: A molding process, other than pultrusion, is used to manufacture composite ladder rails of non-uniform cross-sectional area and non-uniform strength throughout their lengths. Each ladder rail includes a structural fiber preform embedded in a cured polymeric resin. Fiberglass preforms are preferred because they are electrically non-conductive. Resin transfer molding processes, using either polyester or epoxy resins, are ideally suited for such manufacture. Vacuum-bagged, open-mold processes may also be used, as may be compression molding processes. Regions of the rails subject to greater stress during usage are strategically reinforced with additional structural fibers, and have greater cross-sectional area than regions subjected to lesser stress. The differential cross-sectional area permits the construction of ladders which are optimized for both strength and lightness of weight. Ladders of all types may be constructed with rails incorporating the invention.