Flexible risers that carry hydrocarbon fuels from the subsea facilities to the floatation units above the sea surface are composed of multiple metallic and polymeric layers (in their wall). Among these layers, the tensile armour layer consists of several helically wound metallic wires; these tensile armour layers carry the weight of the riser, provide tensile stiffness & strength and maintain the structural integrity of the riser structure during harsh underwater currents. However, as the oil & gas fields in shallow waters are receding, the oil & gas industry is being forced to move towards deeper offshore waters, where the metallic tensile armour wires pose limitations (fatigue, corrosion, weight, etc.). In this thesis an alternative to metallic tensile armour wires will be presented in form of a flexible hybrid composite formed by stacking seven pultruded composite (carbon and vinyl-ester) circular rods in form of hexagonal pack, held together by an over-braid (Dyneema fibres) sleeve. The manufacturing process for hybrid composite tensile armour wires will be studied and their mechanical properties will be presented. A multi-scale finite element model developed for hybrid composite wires will be presented in this thesis to help further understand the mechanical properties of hybrid composite wires.