Full Scale Models and Mock-ups

Full Scale Models and Mock-ups

Aerospace Testing
Accelerated Schedule
Innovative Tooling
State of the Art Testing Facility
In-House Capability
Full Scale Models and Mock-ups

Design and Fabrication of Full Scale Models

Calspan has a rich history of providing full scale models for many vehicle types. Our wide ranging skill sets and in house capabilities have allowed us to support programs from submarine hydrodynamic parts to sled tests and even complete fuselages.

Most of these programs have been composite in nature with some being skin-on-frame construction while others are shaped core with skins. Calspan works with customers to define the critical characteristics early on.

Is exterior appearance and finish most important for a press event? Must stiffness match aircraft values to perform crash or sled testing? Is the model for an RCS test? Calspan can deliver. Our innovative tooling approaches can reduce first unit lead time by months compared to traditional approaches.


Two large autoclaves for curing large components.

Calspan can manufacture custom shop ovens for curing even larger components, up to the physical size of the room.

Full scale aircraft Mock-ups have been manufactured with both female (OML) molds and male (IML) molds.


Expertise in fixed wing, rotorcraft, space and hypersonic models.


Complete fabrication is performed in our 93,000 sq.ft. facility including machining, assembly, instrumentation, inspection and model buy-off.

Design and fabrication services are available for wind tunnel related equipment including: model positioning systems, fan and compressor blades, and tunnel upgrade and overhaul services.

Wind tunnel testing can be performed at Calspan’s Transonic Wind Tunnel in Buffalo, New York.

  • Facility
    • 93,000 square foot secured facility
  • Quality
    • AS9100/ISO9001
    • NADCAP
  • Manufacturing
  • CNC summary
  • Autoclaves
  • Clean rooms
  • Instrumentation lab
  • Large assembly areas



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