To create the best flying model solution, semi-rigid or full-rigid bodies are often necessary. These parts are made of extremely light polyurethane foam which – thanks to its particularly fine fibre structure – can be moulded and shaped to any imaginable form. Firstly, a positive mould is milled using CAD data of the model. The foam is placed over this positive mould and created using a combination of pressure and heat. The moulded parts are then attached to a lightweight chassis that surrounds a custom made inner helium sleeve. The final result is an extremely lightweight and stable replica of the original design.