The main model of the USS Enterprise was eight feet long, to a scale of 1/120th scale size, or 1 inch (2.5 cm) to 10 feet (3.0 m). It took 14 months and $150,000 to build. Instead of standard fiberglass used for older models, the new Enterprise was constructed with lightweight plastics, weighing 85 pounds (39 kg). The biggest design issue was making sure that the connective dorsal neck and twin warp nacelle struts were strong enough so that no part of the ship model would sag, bend, or quiver when the model was being moved, which was accomplished via an arc-welded aluminum skeleton. The completed model could be supported at one of five possible points as each photographic angle required. A second, 20-inch (50.8 cm) model of the ship was used for long shots. While the hull surface was keep smooth, it was treated with a special paint finish that made its surface appear iridescent in certain light.

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