An armor component includes a plurality of tiles disposed on a rigid support. At least one spacer is disposed between the adjacent edges of the tiles to establish a minimum gap between the adjacent edges. The gap is filled with a gap filling material, which optionally includes a reinforcement additive. The spacers can be in the form of a spacer tray having a plurality of spacer segments and a plurality of tile cut-outs, with the tile cut-outs separated from adjacent tile cut-outs by a spacer segment, and tiles disposed one to each tile cut-out in the spacer tray. The armor component is in some embodiments placed between two fabric layers and fed into a pultruder, where it is impregnated with resin and heated to cure the resin to form a laminate armor.