Biomimetic tendon-reinforced” (BTR) composite structures feature improved properties including a very high strength-to-weight ratio. A basic structure comprises a plurality of spaced-apart stuffer members, each having a first end and a second end defining a length. A plurality of tendon elements interconnect with the first and second ends of the stuffer members in alternating fashion, such that the tendon elements criss-cross each other between the stuffer members. A first panel is bonded or attached to the first ends of the stuffer members, and a second panel is bonded or attached to the second ends of the stuffer members. In the preferred embodiments, the first panel, the second panel, or both the first and second panels are curved. An efficient manufacturing process based upon hollow stuffers and tendon elements in the form of bent wires is also disclosed.