US 11,858,661 B2
Method of manufacturing an assembly having a nominal thickness skin panel
Benjamin S. Merrit, Mukilteo, WA (US); Hsien-Lin Huang, Lynnwood, WA (US); Mark Abdouch, Mukilteo, WA (US); Nathan A. Secinaro, Seattle, WA (US); and Daniel Bracy, Everett, WA (US)
Assigned to The Boeing Company, Arlington, VA (US)
Filed by The Boeing Company, Chicago, IL (US)
Filed on Feb. 10, 2022, as Appl. No. 17/650,619.
Prior Publication US 2023/0249844 A1, Aug. 10, 2023
Int. Cl. B64F 5/10 (2017.01); B64C 3/26 (2006.01); B29C 65/78 (2006.01); B64C 1/06 (2006.01); B29D 99/00 (2010.01)
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
OG exemplary drawing
 
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.