Abstract: This paper documents a study aiming to determine if current rapid prototyping methods have capabilities sufficient to produce ballistic models which can be used in wind tunnel testing up to supersonic velocities. Following a critical review of rapid prototyping techniques, several supersonic wind tunnel models were manufactured using the stereo lithography process and Accura Bluestone, a nano-composite, ceramic-filled polymer. To ensure improved physical properties the models were coated in nickel. The presented assessment focuses on aspects of manufacturing and aerodynamics.