Abstract: A method and system provide for reducing gaps between two mating parts. Either or both parts may be nondestructively inspected at a plurality of locations on a surface to gather a data set relating to the part thickness. The data set may be used to calculate a set of as-built thickness values for the part and a set of deviations from a design model. A mating area may be determined for mating surfaces of the parts. One or more layers of sacrificial material in the mating area may be prepared for any deviations greater than a design allowance. The system may include a ply cutting device and an additive manufacturing device coupled to a computer to receive the sacrificial material layer data and shim data and to cut the one or more layers of sacrificial material and to construct the shim. A shim may be constructed for any deviations equal to or greater than a minimum shim thickness. The one or more layers of sacrificial material may be applied to the part, cured, and machined to a desired thickness.

Abstract: A method and system provide for reducing gaps between two mating parts. Either or both parts may be nondestructively inspected at a plurality of locations on a surface to gather a data set relating to the part thickness. The data set may be used to calculate a set of as-built thickness values for the part and a set of deviations from a design model. A mating area may be determined for mating surfaces of the parts. One or more layers of sacrificial material in the mating area may be prepared for any deviations greater than a design allowance. The system may include a ply cutting device and an additive manufacturing device coupled to a computer to receive the sacrificial material layer data and shim data and to cut the one or more layers of sacrificial material and to construct the shim. A shim may be constructed for any deviations equal to or greater than a minimum shim thickness. The one or more layers of sacrificial material may be applied to the part, cured, and machined to a desired thickness.

Abstract: A method and a system are provided for predicting and creating a shim for use in a joint where two parts, such as a skin and a substructure, are assembled together. Digital models for the skin and the substructure may be used as nominal maps of the outlines and profiles of the parts. The skin may be inspected, e.g., by nondestructive means, such as ultrasound, to determine as-built thickness profile for comparison to the skin's digital model of the thickness profile. Mating areas of the skin and substructure may be determined from their digital models of their outlines. Deviations in the mating areas of the as-built thickness of the skin from the digital model of the skin may be used to generate a digital model of a shim. The shim may be constructed from its digital model by additive manufacturing techniques that may involving machining or 3D printing.

Abstract: A method and a system are provided for predicting and creating a shim for use in a joint where two parts, such as a skin and a substructure, are assembled together. Digital models for the skin and the substructure may be used as nominal maps of the outlines and profiles of the parts. The skin may be inspected, e.g., by nondestructive means, such as ultrasound, to determine as-built thickness profile for comparison to the skin's digital model of the thickness profile. Mating areas of the skin and substructure may be determined from their digital models of their outlines. Deviations in the mating areas of the as-built thickness of the skin from the digital model of the skin may be used to generate a digital model of a shim. The shim may be constructed from its digital model by additive manufacturing techniques that may involving machining or 3D printing.