Purpose -The purpose of this paper is to present the benefits offered by rapid prototyping (RP) models for wind-tunnel testing as part of fourth-year aerospace engineering student projects. Ways of overcoming some of the difficulties associated with the 3D printing technology are also discussed. Design/methodology/approach -Polymer-based RP was used to fabricate two-aircraft models, which included stiffening metallic inserts. Testing in a subsonic-wind tunnel was carried out and the results compared to analytic performance predictions. Findings -Low-cost rapid prototypes of wind-tunnel models yielded satisfactory aerodynamic performance. The savings in acquisition cost and time allowed incorporating actual testing in the aircraft design process within the framework of a tight academic budget and schedule. Practical implications -Conducting real-wind-tunnel testing contributes significantly to the educational experience of students; however, it had rarely been carried out when metal model fabrication was the only option. In contrast, RP facilitates an enhanced and more realistic learning experience by offering a quick and affordable means of model manufacturing. Originality/value -Simple methods of reinforcing polymer-based models were incorporated, thus presenting an inexpensive way to test and evaluate preliminary aircraft designs, in both academia and industry.