Methods and systems for forming a shimmed assembly

A method of shimming an uncured substructure for assembly, the method comprising:

• 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;
• predicting a morph of the shape of the mating surface of the substructure that will occur during curing;
• adjusting, based on the predicted morph of the shape of the mating surface, the distances between the plurality of points on the mating surface and respective points on the inner surface of the support structure;
• calculating, based on the adjusted distances between the plurality of points on the mating surface and respective points of an inner surface, a first topographical surface map representing the mating surface and a second topographical surface map representing the inner surface of the support structure;
• performing, based on manufacturing capabilities, predefined gap tolerances, and materials of the substructure and the support structure, a first smoothing process on heights represented by the first topographical surface map and a second smoothing process on heights represented by the second topographical surface map;
• generating filler dimension data using the first topographical surface map and the second topographical map after performing the first smoothing process and the second smoothing process, 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.