For improving the reliability of key components in an airborne pod, gray system theory is introduced into the virtual design of airborne pod. Based on this theory, key components of airborne pod are analyzed and mathematical models of the gray relational model and absolute and relative gray relational model are established, respectively. The differences and relations of the three methods for evaluating the robustness of products are researched. Considering the influence of relevant factors, the change rate of each evaluation index is calculated, and the reliability analysis of the airborne pod body is realized ultimately. Finally, the No. 2 test pod body is the optimal solution, which provides an effective theoretical basis for determining the optimal structure of the airborne pod body.