This paper deals with safety requirements for radiosondes and their possible finite element method (FEM) simulations. This article proposes a soft outer layer, which exhibits the use of a Polyurethane foam (PUR foam) layer on radiosondes. Analysis and tests of normal and PUR foam layer coated radiosonde’s collisions with test targets were done. FEM models were created to model the collisions of radiosondes with virtual targets at drop tests in different scenarios. To compare and verify the virtual results, specified real-life drop test measurements were carried out. The measured data was analyzed and showed an average accuracy of 8% in force measurements, and 2.22% accuracy in duration of the tests. Based on these virtual and real-life tests it was demonstrated, that an FEM model can simulate the end result of using PUR foam layers on radiosondes. It also demonstrated that the applicable PUR foam layer increases a safer collision also increasing the chance of maintaining functionality of the radiosondes.