A method for repairing an airfoil comprising creating a nominal numerically-controlled
tool path based on a nominal shape of the airfoil, measuring the airfoil using
a displacement sensor, capturing differences in the airfoil shape as compared to
the nominal shape, creating a three-dimensional map by synchronizing x, y and z
coordinates and readings from the sensor, modifying the tool path based on the
three-dimensional map, and machining the airfoil. A system for measuring and machining
an airfoil comprising a computer operable for data acquisition and numerically-controlled
tool path generation, a numerically-controlled machine, a cutting tool holder comprising
a plurality of cutting tools, and a displacement-sensing probe.
