Abstract: Design and manufacturing of wind tunnel models are related directly to the accuracy of wind tunnel test data, and also influence period and cost of aircraft development. Lightweight design of low speed wind tunnel models is one of key points to obtain reliable aerodynamic data and lower testing cost. With the structure of frame and beam strengthened composite skins and the additional manufacturing parts, the integral and lightweight model of civil aircraft is designed. The finite element analysis is used to calculate the structure intensity and vibration analysis is conducted. It concludes that the weight of the model is reduced by 50% compared to that of the conventional metal model, and meanwhile the structure intensity of the model satisfies design requirements. The irregular shaped part is designed with additional manufacturing method, the weight of which is reduced by 20% and the manufacturing period is shortened by more than 50% compared to that for composite model. The inherent frequency of the model-support system is increased compared to that of metal model.