Abstract: An aircraft skin alignment system includes at least one support structure to support one or more aircraft skins and one or more assembly tools; the one or more assembly tools having a holding mechanism to releasably engage with a first aircraft skin; a pulling mechanism to apply a pulling force to the first aircraft skin; and an edge locator; the pulling mechanism is to pull the first aircraft skin such that a first edge of the first aircraft skin abuts the edge locator, the edge locator preventing the first edge from being pulled past the edge locator; and one or more tool holes can be drilled into the first aircraft skin such that the one or more tool holes are aligned based on an edge index due to a position of the edge locator.

Abstract: An aircraft skin alignment system includes at least one support structure to support one or more aircraft skins and one or more assembly tools; the one or more assembly tools having a holding mechanism to releasably engage with a first aircraft skin; a pulling mechanism to apply a pulling force to the first aircraft skin; and an edge locator; the pulling mechanism is to pull the first aircraft skin such that a first edge of the first aircraft skin abuts the edge locator, the edge locator preventing the first edge from being pulled past the edge locator; and one or more tool holes can be drilled into the first aircraft skin such that the one or more tool holes are aligned based on an edge index due to a position of the edge locator.

Abstract: An aircraft skin alignment system includes a support structure to support one or more aircraft skins, a puller tool, and a clamp tool; the puller tool having a base, the base supporting a holding mechanism to releasably engage with a first aircraft skin and a pulling mechanism to apply a pulling force to the first aircraft skin when the first aircraft skin is engaged with the holding mechanism; and the clamp tool having a body supporting an edge locator; the puller tool is to pull the first aircraft skin such that a first edge of the aircraft skin abuts the edge locator, the edge locator preventing the first edge from being pulled past the edge locator; and tool holes can be drilled into the first aircraft skin such that the tool holes are aligned based on an edge index due to a position of the edge locator.

Abstract: An exchangeable forming component is configured for removable mounting relative to an interface block of a modular forming tool, with the interface block of the modular forming tool configured for removable mounting relative to a support structure to form a sheet metal component. The exchangeable forming component includes a component structure which is constructed using additive manufacturing, wherein the exchangeable forming component presents a first surface which provides an exchangeable forming surface shaped to form the sheet metal component, and a second surface configured to removably engage the support structure.

Abstract: An aircraft skin alignment system includes a support structure to support one or more aircraft skins, a puller tool, and a clamp tool; the puller tool having a base, the base supporting a holding mechanism to releasably engage with a first aircraft skin and a pulling mechanism to apply a pulling force to the first aircraft skin when the first aircraft skin is engaged with the holding mechanism; and the clamp tool having a body supporting an edge locator; the puller tool is to pull the first aircraft skin such that a first edge of the aircraft skin abuts the edge locator, the edge locator preventing the first edge from being pulled past the edge locator; and tool holes can be drilled into the first aircraft skin such that the tool holes are aligned based on an edge index due to a position of the edge locator.

Abstract: A method of locating a stake to a floor assembly jig includes providing a floor assembly jig and a stake having a plurality of segments, laser cutting one or more slots into a structural member of the floor assembly jig, inserting at least one segment of the stake into the one or more slots thereby providing a substantially precise position and alignment of the stake with respect to the floor assembly jig, and securing the stake to the floor assembly jig to maintain the substantially precise position and alignment of the stake.