Sabots are used in gas guns to hold bird and hail projectiles in aerospace component test. Sabots used for bird and hail projectiles are classified by their construction into split and single piece sabot. Design procedure for split and single piece sabot are highly empirical and depends on the type of projectile. Design methodology is developed for split sabot and the relation between sabot dimensions, geometric features, density of the sabot material, number of sabot pieces, velocity of sabot at the gun exit and the radial travel distance during the travel between gas gun barrel exit and test article are calculated. This methodology is validated using explicit finite element simulation of an axisymmetric model of sabot and projectile exiting the gas gun barrel. Design methodology of the single piece sabot is different from split sabot and depends more on the sabot material properties. Analytical formulation for single piece sabot design is discussed. Three dimensional explicit finite element simulations are carried out to validate the design procedure and the relation between the sabot stopping distance, sabot material and the design parameters of the sabot catcher system are discussed. © 2017 Elsevier Ltd.