FeAl-based MIL composites of various iron alloys were fabricated with an innovative "multiple-thin-foil" configuration and "two-stage reaction" strategy. Alternating stacked metal foils were reactive sintered via SPS at 600 o C and 1000 o C to grow intermetallics. The "multiple-thin-foil" configuration reduces reaction time, enables local chemical composition control and allows metal/intermetallic combinations, which cannot be produced via the conventional methods. Fe-FeAl, 430SS-FeAl, and 304SS-FeAl MIL composites can be synthesized with desired metallic/intermetallic ratios, where FeAl is the single intermetallic phase present in the composites. Microstructure analysis via SEM, EDS, and EBSD confirms phase identification and reveals the formation of transition layers. The transition layer, which incorporates the composition gradient between the metal (Fe, 430SS or 304SS) and the FeAl intermetallic phase, provides a gradual change in mechanical properties from the metal to intermetallic layers, and further functions as a chemical barrier into which other undesired intermetallics dissolve. Driven by diffusioncontrolled growth, grains in the transition layers and FeAl regions exhibit ordered arrangement and sintering textures. Hardness profiles from the metal layer to FeAl region 2 reveal the correlation between local mechanical properties and local chemical compositions. In compression testing, the compressive strength can reach 2.3 GPa with considerable plasticity, establishing the best mechanical properties of any MIL composites synthesized to date.Metal-intermetallic laminate (MIL) composites are produced via incorporating layers of ductile metals into strong, but brittle intermetallics for optimizing mechanical behaviors.Generally, aluminide-intermetallics possess ordered crystalline structures with high specific modulus and high specific compressive strength, but often very limited plasticity or toughness. Reinforcing these intermetallics with particles, fibers or layers of ductile metals can enhance the toughness [1], making the materials more efficient for structural applications.MIL composites are typically synthesized via hot pressing alternating stacked metal foils so that intermetallic layers form as the result of interdiffusion and chemical reaction, while an appropriate pressure ensures intimate contact between the sheets of metal foils. The selection of the foil composition and thickness can determine the physical and mechanical properties of the MIL composites so that the specific performance requirements can be 3 fulfilled. The ability to tailor composite microstructure, and the low cost of the initial metallic foils make MIL composites ideal as commercially scalable structural materials, suitable for aerospace applications that require lightweight materials with high specific properties. By tuning the geometry of the initial metal foils, MIL composites can be synthesized into complex shapes, such as rods, tubes or cones, for specific platforms. In addition, multi-functionality can be incorporated...