Abstract: In an example, a method of shimming an uncured substructure for assembly is disclosed. The method comprises emitting a signal from an inspection system proximate a mating surface of the substructure, detecting a reflection of the signal with the inspection system, generating a data set based on detecting the reflection of the signal, the data set representing a shape of the mating surface, determining distances between a plurality of points on the mating surface and respective points on an inner surface of a support structure based on the data set, generating filler dimension data based on the distances, wherein the filler dimension data includes a varying thickness, shaping a filler structure with a computer numerical controlled shaping device using the filler dimension data, adhering a first surface of the filler structure to the mating surface of the substructure to form a shimmed substructure subassembly, and curing the shimmed substructure subassembly.