Repair of aerospace components represents a significant opportunity for hybrid manufacturing systems to reduce high scrap rate through automation of the inspection, additive and subtractive processes. In this study, a series of on-machine profile digitization strategies were investigated to determine the effects on accuracy of non-rigid registration of blade component geometry and downstream quality measures pertaining to parent material blendlines. The profile digitization strategies investigated include dense sampling methods and curvature-based segmentation approaches. A model was developed to predict the accuracy of the digitization approaches and a series of machining tests were also conducted to show the predictive capability of the model. From these results, it is seen that curvature-based segmentation methods provide an accurate and rapid digitization solution for blend-type repairs.
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