Abstract: A system for fabricating a double-contoured shim includes a model generator and a manufacturing system. The model generator generates a shim model to fill a gap between a first mating-surface and a second mating-surface. The model generator generates a virtual plane that divides the shim model into a first shim model and a second shim model. A first shim is fabricated based on the first shim model. The first shim includes a first contoured shim-surface that is complementary to a first mating-surface area of the first mating-surface and a first planar shim-surface that is opposite the first contoured shim-surface. A second shim is fabricated based on the second shim model. The second shim includes a second contoured shim-surface that is complementary to a second mating-surface area of the second mating-surface and a second planar shim-surface that is opposite the second contoured shim-surface.

Abstract: A manufacturing system includes a holding structure and actuators that are coupled to the holding structure. The actuators support the component and apply displacements to select locations of the component to change a current shape of the component toward a target shape of the component. The system includes a metrology system that takes measurements of the current shape of the component. The system includes a controller that utilizes a closed feedback loop to determine a deviation between the current shape and the target shape based on the measurements and to provide commands that iteratively change the displacements in response to changes in the current shape until the current shape is within a tolerance of the target shape.

Abstract: A pressure bulkhead assembly for an aircraft includes an aft pressure bulkhead and a plurality of splice angles. The aft pressure bulkhead includes a bulkhead interface surface and aft-pressure-bulkhead holes, pre-drilled through the bulkhead interface surface. The plurality of splice angles is configured to be coupled to the aft pressure bulkhead. Each one of the plurality of splice angles includes a flange surface, configured to mate with the bulkhead interface surface. Each one of the plurality of splice angles also includes splice-angle holes, drilled through the flange surface. Each one of the plurality of splice angles further includes a splice surface, extending from the flange surface. With the splice-angle holes aligned with the aft-pressure-bulkhead holes, a plurality of splice surfaces forms a circumferential splice surface with an optimized shape.

Abstract: A method for making a pressure bulkhead assembly of an aircraft includes determining first locations and first orientations of a plurality of first holes, pre-drilled in an aft pressure bulkhead. The method also includes determining a first surface profile of a first interface surface of the aft pressure bulkhead and determining a second surface profile of a second interface surface of each one of a plurality of splice angles. The method also includes determining second locations and second orientations of a plurality of second holes to be drilled in each one of the plurality of splice angles corresponding to the plurality of first holes in the aft pressure bulkhead and drilling the plurality of second holes in each one of the plurality of splice angles at the second locations and second orientations.

Abstract: A method of making a pressure bulkhead assembly of an aircraft includes determining an optimized position of splice angles such that splice surfaces of the splice angles will form a circumferential splice surface of the pressure bulkhead assembly with an optimized shape. The method further includes performing a virtual fit between the plurality of splice angles, at the optimized position, and an aft pressure bulkhead. The method also includes determining splice-angle-hole positions of splice-angle holes to be drilled in each one of the splice angles such that the splice-angle holes will correspond to aft-pressure-bulkhead holes, pre-drilled in the aft pressure bulkhead. The method further includes drilling the splice-angle holes in each one of the splice angles at the splice-angle-hole positions. The method also includes joining each one of the splice angles with the aft pressure bulkhead such that the splice surfaces form the circumferential splice surface with the optimized shape.

Abstract: A method of making a pressure bulkhead assembly of an aircraft includes determining an optimized position of splice angles such that splice surfaces of the splice angles will form a circumferential splice surface of the pressure bulkhead assembly with an optimized shape. The method further includes performing a virtual fit between the plurality of splice angles, at the optimized position, and an aft pressure bulkhead. The method also includes determining splice-angle-hole positions of splice-angle holes to be drilled in each one of the splice angles such that the splice-angle holes will correspond to aft-pressure-bulkhead holes, pre-drilled in the aft pressure bulkhead. The method further includes drilling the splice-angle holes in each one of the splice angles at the splice-angle-hole positions. The method also includes joining each one of the splice angles with the aft pressure bulkhead such that the splice surfaces form the circumferential splice surface with the optimized shape.

Abstract: A method for making a pressure bulkhead assembly of an aircraft includes determining first locations and first orientations of a plurality of first holes, pre-drilled in an aft pressure bulkhead. The method also includes determining a first surface profile of a first interface surface of the aft pressure bulkhead and determining a second surface profile of a second interface surface of each one of a plurality of splice angles. The method also includes determining second locations and second orientations of a plurality of second holes to be drilled in each one of the plurality of splice angles corresponding to the plurality of first holes in the aft pressure bulkhead and drilling the plurality of second holes in each one of the plurality of splice angles at the second locations and second orientations.

Abstract: A method includes making a first structure with a first plurality of pre-drilled holes at pre-defined locations, making a second structure with a second plurality of pre-drilled holes at pre-defined locations, making a third structure without pre-drilled full-size holes, measuring the location and orientation of the first and second plurality of pre-drilled holes in the first and second structures, determining the location of a third plurality of holes to be drilled in the third structure that correspond to first and second plurality of pre-drilled holes measured in the first and second structures, creating a program to drill the third plurality of holes in the third structure that align with the measured location and orientation of the first and second plurality of pre-drilled holes in the first and second structures based on the measure location and orientation of the first and second plurality of pre-drilled holes in the first and second structure, drilling the third plurality of holes in the third structu

Abstract: A method includes making a first structure with a first plurality of pre-drilled holes at pre-defined locations, making a second structure with a second plurality of pre-drilled holes at pre-defined locations, making a third structure without pre-drilled full-size holes, measuring the location and orientation of the first and second plurality of pre-drilled holes in the first and second structures, determining the location of a third plurality of holes to be drilled in the third structure that correspond to first and second plurality of pre-drilled holes measured in the first and second structures, creating a program to drill the third plurality of holes in the third structure that align with the measured location and orientation of the first and second plurality of pre-drilled holes in the first and second structures based on the measure location and orientation of the first and second plurality of pre-drilled holes in the first and second structure, drilling the third plurality of holes in the third structu

Abstract: A method includes making a first structure with a first plurality of pre-drilled holes at pre-defined locations, making a second structure with a second plurality of pre-drilled holes at pre-defined locations, making a third structure without pre-drilled full-size holes, measuring the location and orientation of the first and second plurality of pre-drilled holes in the first and second structures, determining the location of a third plurality of holes to be drilled in the third structure that correspond to first and second plurality of pre-drilled holes measured in the first and second structures, creating a program to drill the third plurality of holes in the third structure that align with the measured location and orientation of the first and second plurality of pre-drilled holes in the first and second structures based on the measure location and orientation of the first and second plurality of pre-drilled holes in the first and second structure, drilling the third plurality of holes in the third structu

Abstract: A system for measuring a flushness of a fastener in a surface includes a plurality of lights configured to illuminate the fastener and the surface. The system also includes a camera configured to capture a plurality of images of the fastener and the surface while the lights sequentially illuminate the fastener and the surface. The system also includes a computing system configured to determine a normal map of the fastener and the surface based at least partially upon the images, determine a depth map of the fastener and the surface based at least partially upon the normal map, and determine the flushness of the fastener with respect to the surface based at least partially upon the depth map.

Abstract: A system for measuring a flushness of a fastener in a surface includes a plurality of lights configured to illuminate the fastener and the surface. The system also includes a camera configured to capture a plurality of images of the fastener and the surface while the lights sequentially illuminate the fastener and the surface. The system also includes a computing system configured to determine a normal map of the fastener and the surface based at least partially upon the images, determine a depth map of the fastener and the surface based at least partially upon the normal map, and determine the flushness of the fastener with respect to the surface based at least partially upon the depth map.

Abstract: Methods for using predictive shimming to optimize part-to-part alignment. In accordance with one embodiment, the process uses measurement data acquired from mating surfaces and key features to virtually align two parts in a manner that optimizes the final orientation of the parts and determines the geometry of the shim needed to achieve this orientation during assembly.

Abstract: Systems and methods are provided for placing non-destructive marks onto a part via an end effector of a robot. One embodiment is a system comprising an end effector of a robot. The end effector includes an extendable punch that places targets onto a part, and supports that hold a strip of reflective adhesive tape between the punch and the part. Extending the punch cuts out a target from the strip and applies an adhesive side of the target to the part, and retracting the punch leaves a reflective side of the target visible on the part.

Abstract: A method includes making a first structure with a first plurality of pre-drilled holes at pre-defined locations, making a second structure with a second plurality of pre-drilled holes at pre-defined locations, making a third structure without pre-drilled full-size holes, measuring the location and orientation of the first and second plurality of pre-drilled holes in the first and second structures, determining the location of a third plurality of holes to be drilled in the third structure that correspond to first and second plurality of pre-drilled holes measured in the first and second structures, creating a program to drill the third plurality of holes in the third structure that align with the measured location and orientation of the first and second plurality of pre-drilled holes in the first and second structures based on the measure location and orientation of the first and second plurality of pre-drilled holes in the first and second structure, drilling the third plurality of holes in the third structu

Abstract: Systems and methods are provided for placing non-destructive marks onto a part via an end effector of a robot. One embodiment is a system comprising an end effector of a robot. The end effector includes an extendable punch that places targets onto a part, and supports that hold a strip of reflective adhesive tape between the punch and the part. Extending the punch cuts out a target from the strip and applies an adhesive side of the target to the part, and retracting the punch leaves a reflective side of the target visible on the part.

Abstract: Methods for using predictive shimming to optimize part-to-part alignment. In accordance with one embodiment, the process uses measurement data acquired from mating surfaces and key features to virtually align two parts in a manner that optimizes the final orientation of the parts and determines the geometry of the shim needed to achieve this orientation during assembly.

Abstract: A fuel injector nozzle assembly is disclosed. The assembly may include a nozzle casing, a first tip member, and a second tip member. The first tip member may extend longitudinally within the nozzle casing and may define first and second shoulders on the first tip member. The second tip member may extend longitudinally within the nozzle casing and may be arranged in predetermined rotational alignment with the first tip member. The second tip member may define a third shoulder on the second tip member configured to interact with the first shoulder to oppose rotation of the first tip member relative the second tip member in a first direction about a longitudinal axis of the first tip member. The second tip member may further define a fourth shoulder on the second tip member configured to interact with the second shoulder to oppose rotation of the first tip member relative the second tip member in a second direction about a longitudinal axis of the first tip member.