Abstract The use of multi-functional integral armor is of current interest in armored vehicles and military carriers. In the present study, thick-section laminated composites and multi-layered integrated composites have been processed/manufactured with the aim of providing multi-functionality including easy reparability, quick deployment, enhanced ballistic damage and fire protection, as well as lightweight advantages. The design of an integral armor utilizes a combination of thick-section structural composite, ceramic tiles, resilient rubber, fire retardant laminate liner and a composite durability cover. Processing techniques such as automated fiber placement and/or autoclave molding are traditionally used to process dissimilar multi-layered structure, but prove to be expensive. This work focuses on emerging cost-effective liquid molding processes such as vacuum assisted resin transfer/infusion molding (VARTM) for the production of thick-section and integral armor parts (up to 50 mm thick). While thick-section composites have applications in a variety of structures including armored vehicles, marine bodies, civil infrastructure, etc. in the present work they refer to the structural laminate within the integral armor. The processing steps of thick-section composite panels and integral armor have been presented. The integrity of the interfaces has been evaluated through scanning electron microscopy (SEM). Representative results on static and dynamic response (high strain rate, HSR and ballistic impact) of the VARTM processed thick-section composite panels are presented. Wherever applicable, comparisons are made to conventional closed-mold resin transfer molding (CMRTM). Process sensing by way of flow and cure monitoring of the resin in the fiber perform has been conducted using embedded direct current (DC)-based sensors in the thick-section preform and integral armor interfaces. The feasibility of cost-effective VARTM for producing thick-section composites and integral armor has been demonstrated.