3D printed wind tunnel models — dimensionally accurate aerodynamic test models at scale.
Wind tunnel testing requires models with precise geometry and smooth surfaces. Our Industrial SLA platform produces wind tunnel models up to ~1000mm with the dimensional accuracy and surface finish that aerodynamic testing demands. Smooth, sealed surfaces eliminate the boundary layer disturbances caused by layer lines.
Challenges we solve
What wind tunnel models teams need from a 3D printing service
Achieving aerodynamic-grade surface finish
Surface roughness affects boundary layer transition and test validity. Industrial SLA delivers 2 Ra μm as-printed. With post-processing, we achieve polished surfaces suitable for the most demanding aerodynamic testing.
Maintaining dimensional accuracy at scale
Wind tunnel models must accurately represent the full-scale geometry. Industrial SLA holds tight tolerances across the full build volume, and we can provide dimensional verification on critical features.
Producing models with integrated mounting features
Wind tunnel models need sting adapters, strut mounting points, or floor mounting provisions. We integrate these features into the build — no post-machining required for most configurations.
Iterating model configurations
Aerodynamic development often requires multiple model configurations. Reprint a modified model instead of re-machining — faster iteration at lower cost.
Technologies
Best technologies for wind tunnel models
Materials
Materials for wind tunnel models
ABS-Like Resin on Industrial SLA for optimal surface finish and dimensional accuracy. Rigid 10K for models requiring maximum stiffness to resist aerodynamic loading. High Temp for models tested in heated wind tunnels.
ABS-Like Resin
Industrial SLA · Shore D 79
Tough, impact resistant. Good for large functional parts, enclosures, and assemblies.
Rigid 10K
SLA · Shore D 90
Highly glass-filled. Stiffest SLA material. For precise industrial parts under significant load.
High Temp
SLA · Shore D 85
HDT 238°C. Molds, tooling, and parts exposed to heat.
Common parts
What we build for wind tunnel models
Built in our factory
Brooklyn, NY
How it works
Your project, step by step
Submit model geometry
Upload CAD with scale, mounting configuration, and critical dimension callouts.
Build plan
We optimize orientation for surface quality on aerodynamic surfaces and plan mounting feature integration.
Model produced on Industrial SLA with orientation locked for surface quality.
Finish & verify
Aerodynamic surfaces polished. Critical dimensions verified. Mounting features checked for fit.
Ship
Model packed in protective crating for transit to your test facility.
FAQ
Frequently asked questions
Is the surface finish smooth enough for valid testing?
Industrial SLA delivers 2 Ra μm as-printed. With polishing, we achieve near-mirror surfaces suitable for the most sensitive aerodynamic measurements.
Can you integrate pressure tap locations?
Yes. We can print pressure tap ports directly into the model geometry. Provide tap locations in your CAD file and we integrate them into the build.
What about model stiffness under aerodynamic loads?
Rigid 10K resin provides 10 GPa tensile modulus for models that must resist deflection under load. For very high-load applications, we can recommend metal inserts or hybrid construction.
Other applications
Rapid Prototyping
Functional prototypes in 2–3 business days. Test form, fit, and function before committing to tooling.
Production Parts
Production-grade 3D printed parts at volume — without tooling investment.
Hardware Development
One vendor from first prototype to production parts — no retooling, no requalifying.
Large Format 3D Printing
Single pieces up to 1200mm — or seamless multi-part assemblies at any scale.
Tooling & Fixtures
Custom jigs, fixtures, and assembly aids — delivered in days, not weeks.
Bridge Manufacturing
Ship real product now. Transition to injection molding when you are ready.
Replacement & Spare Parts
Reproduce legacy parts, replace obsolete components, and eliminate spare parts inventory.
Custom Enclosures
Custom enclosures with snap-fits, bosses, and ventilation — production-grade, no tooling.
Low Volume Manufacturing
Manufacture 10 to 5,000 parts without tooling — scale up or down order by order.
Presentation Models & Props
Presentation-quality models, trade show props, and display pieces — finished and delivered on time.
Casting Patterns
3D printed casting patterns — clean burnout, fine detail, no traditional pattern tooling.
Medical & Anatomical Models
Anatomical models, surgical planning aids, and medical training tools — dimensionally accurate.
End-Use Consumer Products
Ship real products to real customers — without injection mold tooling.
Design Verification & Testing
DVT and EVT builds in production-representative materials — validate before you tool.
Product Design Validation
Test form, fit, and function with production-grade materials before committing to tooling.
Investor Samples
Presentation-quality parts that look and feel like the final product — built for boardrooms, pitch decks, and demo days.
Pre-Production Testing
Validate tolerances, material behavior, and assembly flow at low volume before committing to production.
Jigs and Fixtures
Custom tooling for your production line — printed and delivered in days, not weeks.
End-Use Production Parts
Parts that go directly into products your customers buy and use — not prototypes, not samples.
Supply Chain Supplementation
Fill gaps in your supply chain without retooling or waiting months for overseas shipments.
Low-Volume Serial Production
Hundreds to thousands of identical parts — no MOQ from a mold shop, no tooling investment.
Replacement Parts Programs
On-demand spares for legacy and current products — without warehousing inventory.
Architectural Models
Site models, facade studies, and presentation pieces at true scale — printed whole or assembled seamless.
Trade Show Builds
Oversized displays and product replicas built to withstand transport and handling — show-ready finish.
Industrial Housings and Enclosures
Full-size prototypes of panels, covers, and housings — validate before committing to sheet metal or tooling.
Tooling and Molds
Large-format mold masters and lay-up tools — printed faster than machined.
Props and Set Pieces
Camera-ready props for film, TV, and commercial production — on tight timelines.
Legacy Part Replacement
Reverse-engineer and reproduce discontinued parts from scans or drawings — no original tooling needed.
Part Consolidation
Combine multi-part assemblies into single printed components — fewer parts, fewer failure points.
Lightweighting
Topology optimization and lattice structures — cut weight without cutting strength.
Manufacturability Analysis
Evaluate your design for printability before committing to a production run.
Scan-to-CAD
Point cloud in, watertight solid out — production-ready CAD from any 3D scan.
Tooling Design
Custom jigs, fixtures, and mold masters — designed from scratch for additive manufacturing.
Fixture Optimization
Redesign production fixtures to reduce weight, improve ergonomics, and speed up assembly.
Plan Your Project
Tools to plan your build
Check shipping transit times, estimate lead times by technology, and review design guidelines before you upload — so your parts print right the first time.
Check Transit Time
Enter your zip code to see how fast parts arrive from our Brooklyn facility.
Ready to start your wind tunnel models project?
Upload your CAD file and get a quote in minutes — or talk to our engineers about your next production run.