© 2022 Elsevier LtdIn this study, a numerical methodology is developed to monitor stress distributions and an experimental technique is investigated to measure stresses on metal embedded polymer matrix fiber-reinforced composite materials using X-ray diffraction (XRD) method. The numerical method successfully predicts the stress distributions using only a few data points with an average accuracies of 11.6% and 11.8%, respectively for tapered and open hole tensile sample geometries. Experimental part of this study investigates different methodologies to measure stresses on surfaces of polymer composites materials of thin walled structures by XRD. For this reason, metallic materials were integrated onto the surface and near-surface of polymer matrix composites in three different configurations as in the forms of metal foil, metal powder, and metal wire mesh. In-situ experiments of measured and applied stresses revealed metal powder embedded composite materials as a promising material configuration for reliable monitoring of stresses.