Purpose　The　purpose　of　this　paper　is　to　present　a　novel　method　to　design　and　manufacture　rapid　prototyping　(RP)　lightweight　photopolymer-resin　models　for　wind-tunnel　tests.　This　method　can　ensure　the　structural　configuration　similarity　considering　model　deformation　under　aerodynamic　loads.　Design/methodology/approach　Photopolymer-resin　based　on　RP　technique　was　used　to　fabricate　DLR-F4　models.　Testing　in　a　subsonic　and　transonic　wind　tunnel　was　carried　out　and　the　test　results　were　compared　to　analyze　performance　predictions.　Findings　RP　photopolymer-resin　wind-tunnel　models　fabricated　by　the　design　methods　yielded　satisfactory　aerodynamic　performance.　The　methods　can　decrease　the　model＇s　weight　and　prevent　resonance　occurrence　among　the　models,　wind-tunnel,　and　support　system,　shorten　the　processing　period,　and　lead　to　decrease　in　manufacturing　period　and　cost.　Research　limitations/implications　Stiffness　shortage　of　the　thin　components,　such　as　wing　tip,　often　leads　to　deformation　occurrence　under　aerodynamic　loads　in　transonic　wind-tunnel　tests,　which　has　significant　influence　on　aerodynamic　characteristics　of　the　test　models.　Therefore,　model　deformation　should　be　taken　into　account　in　the　design　process.　Originality/value　This　design　and　manufacture　method,　aerodynamic　and　structural　combination　design　and　structural　optimization,　can　obtain　RP　lightweight　photopolymer-resin　wind-tunnel　models　for　satisfactory　aerodynamic　performance,　which　makes　RP　techniques　more　practical　for　manufacturing　transonic　wind-tunnel　test　models,　considering　deformation　induced　by　aerodynamic　forces　such　as　lift　force.　The　methods　also　present　an　inexpensive　way　to　test　and　evaluate　preliminary　aircraft　designs,　in　both　academia　and　industry.