Flexible composite

A flexible composite that can be set to become rigid or semi-rigid, the composite comprising:

• a first layer;
• a second layer opposing the first layer and separated from the first layer by a space;
• a powder fill material located in the space between the first and second layers, which is capable of setting to a rigid or semi-rigid solid on the addition of a liquid, gas or radiation;
• a plurality of elements extending substantially into the space from and connected to at least one of the first layer and the second layer and form linking elements which join the first layer and the second layer together, the linking elements defining first points in the first layer and second points in the second layer of localized minima in an outward separation between the first layer and the second layer;
• and
• a first plurality of curved tensile microstructures in the first layer between the first points of localized minima in the first layer, the first plurality of curved tensile microstructures extending away from the second layer;
• wherein the first plurality of curved tensile microstructures are formed from the unset powder fill material provided in the space at a pressure such that tension is applied to the linking elements between the first layer and the second layer;
• and
• wherein the flexible composite being transportable with the powder fill material unset in the space prior to setting of the powder fill material by adding liquid, gas or radiation.