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Wind tunnel testing is important for aerosol sampling studies. The goal of this study was to design a wind tunnel that meets the USEPA requirements: the maximum deviation of both the aerosol concentration and the velocity from the mean should be less than 10% at the cross sectional working area. Several challenges are associated with the wind tunnel design. First, the design of the air mixer is difficult since there is few scientific relationship between the mixing efficiency and the mixing distance. Second, if a big wind tunnel is built using a poor design, it will be expensive and time consuming to modify or rebuild it. Therefore, a 1:5 scale tunnel was built to predict the behavior of the full-scale module. From the experiments carried out in the small wind tunnel, a Generic Tee Plenum System (GTPS) was found to be a good mixer with a coefficient of variance (COV) of 2.5% in the testing area. When employing a modified shape inlet to the GTPS or adding a double air blender downwind of the GTPS, the deviation of the velocity from the mean was found to be less than 10%. Based on the result of the small scale test, a full-scale wind tunnel has been built. It is expected that the full-scale wind tunnel will meet the USEPAs requirements with few modifications.