CPC B64F 5/10 (2017.01) [B29C 65/7808 (2013.01); B29D 99/0014 (2013.01); B64C 1/064 (2013.01); B64C 1/065 (2013.01); B64C 3/26 (2013.01)] | 20 Claims |
14. A method of manufacturing a panel assembly, comprising:
supporting a panel assembly in a free state using a holding fixture, the panel assembly comprising a skin panel, and sacrificial material coupled to a skin panel inner surface respectively at interface locations for coupling the panel assembly to mating structure;
acquiring a free state outer surface contour of the panel assembly by scanning a skin panel outer surface of the skin panel while the panel assembly is supported by the holding fixture;
developing a numerical control (NC) machining program having cutter paths configured for machining the interface locations to an inner surface contour that is based on the free state outer surface contour;
machining the sacrificial material by moving a cutter along the cutter paths while the panel assembly is supported by the holding fixture, and while the cutter is backed by a backing device applying backing pressure against the skin panel outer surface while the backing device moves in a coordinated manner in alignment with the cutter as the cutter moves along the cutter paths on the opposite side of the skin panel;
removing the panel assembly from the holding fixture; and
indexing the panel assembly and the mating structure to each other, and fastening the panel assembly and the mating structure together to result in a structural assembly.
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