Abstract: A method of constructing an aerostat involves using a self-mating adhesive system to bind a first barrier film and a second barrier film together. The adhesive precursors of the self-mating adhesive system are applied to the first and second barrier films at the desired point of bonding between the films. Following the application of the adhesive precursors, the barrier films are pressed together to bring the adhesive precursors into contact with each other. A self-mating adhesive layer, which binds the first and second barrier films together, is formed as a result of the reaction between the adhesive precursors. Thereafter the aerostat is die cut out of the web film. The method of the present invention results in aerostats with a bond line at the edge of the desired shape. These aerostats have a reduced weight compared to aerostats made using conventional practices employing a heat sealing layer.