Materials and Methods for Building Aerospace Mockups – The Professional Approach of Sela Projects

Manufacturing high-fidelity mockups for EW pods, radar pods, radomes, and various aeronautical systems requires precise engineering, in-depth material knowledge, and the ability to translate complex systems into accurate display models.
At Sela Projects, we apply industry-standard production methods commonly used in aerospace and defense, tailoring each technique to the geometry and functional needs of every component.

The following overview presents our professional approach to designing and manufacturing high-quality mockups.

1. Large-Scale Structural Parts Made from Ureol (Renshape / PU Modeling Board)

Ureol is a widely used industrial modeling material in the aerospace, automotive, and defense industries. It serves as the primary material for the outer shell and large body components of mockups and pod structures.

Why Ureol Is the Preferred Material

• Excellent CNC machinability – enables accurate aerodynamic shapes and precise geometry.

• Superior surface quality – supports high-end paint finishes that closely emulate the real system.

• High dimensional stability – essential for large pod structures, radomes, and external housings.

• Ideal for large external forms such as EW pods, radar pods, antenna fairings, and full-scale housings.

This method is perfectly suited for:
main shells, aerodynamic bodies, and large structural components.

2. 3D Printing for Small and Highly Detailed Components

Alongside CNC machining, we integrate industrial 3D printing for small, intricate, or highly detailed parts.

Why Use 3D Printing?

• Produces fine details and complex geometries that are difficult or inefficient to mill

• Allows material selection based on rigidity, texture, and required surface properties

• Enables fast, precise production of internal elements and decorative features

• Complements Ureol structures to create a complete and realistic mockup

This approach is ideal for:
connectors, detailed housings, small covers, internal components, and technical decorative parts.

3. Combining Materials for a Realistic, Authentic Appearance

Although the CDR (Critical Design Review) has not yet been completed, our intention is to use a broad combination of materials to achieve maximum realism—both visually and physically.

This includes:

• Metal inserts or CNC-machined aluminum parts for mounting points or structural reinforcement

• Rubber components for seals, straps, and interface details

• Additional materials selected according to functional or aesthetic requirements

This multi-material approach allows us to:

✔ Accurately replicate textures, structures, and interfaces
✔ Maintain a practical weight for transport and exhibitions
✔ Preserve high visual fidelity
✔ Deliver a model that closely matches the real operational system

Conclusion – A Professional, Industry-Standard Mockup Methodology

By combining Ureol machining, advanced 3D printing, and strategic material integration, we are able to manufacture mockups that are:

• Engineered with high precision

• Finished to exhibition-grade quality

• Lightweight and easy to handle

• Faithful to the appearance and proportions of the real product

At Sela Projects, we adhere to the same production standards used across the global aerospace industry, ensuring each mockup meets the technical, visual, and operational expectations of our clients.