Pressure bulkhead assembly and method and system for making the same

A method of making a pressure bulkhead assembly of an aircraft includes determining an optimized position of splice angles such that splice surfaces of the splice angles will form a circumferential splice surface of the pressure bulkhead assembly with an optimized shape. The method further includes performing a virtual fit between the plurality of splice angles, at the optimized position, and an aft pressure bulkhead. The method also includes determining splice-angle-hole positions of splice-angle holes to be drilled in each one of the splice angles such that the splice-angle holes will correspond to aft-pressure-bulkhead holes, pre-drilled in the aft pressure bulkhead. The method further includes drilling the splice-angle holes in each one of the splice angles at the splice-angle-hole positions. The method also includes joining each one of the splice angles with the aft pressure bulkhead such that the splice surfaces form the circumferential splice surface with the optimized shape.