Aero-engine turbine blades are vulnerable to be damaged due to the serving environment of high temperature

high pressure and high speed. At present

the repair technologies of damaged blades have been a hotspot in the aircraft maintenance. In this paper

a method of remanufacturing and repairing aero-engine blades based on reverse engineering is studied by taking a turbine blade as an example. The target repairing surface reconstructed in this method based on non-damaged blade serving at the same time instead of the original design model will more accord with deformation state of damaged blades. Firstly

the damaged blade and non-damaged blade serving at the same time are scanned by the 3D blue-light scanner and the point cloud model of two blades can be acquired. Secondly

the repairing area and boundary can be identified after best fitting. And then

the errors between these two blades in repaired area will be predicted according to polynomial curves fitted by these errors in non-repaired area after registration. Furtherly

the section curves of target repairing surface can be obtained based on the predicted errors and section curves of non-damaged blade. Finally

the target repairing surface can be constructed using the skin method. And the constructed surface is used for the generation of NC tool paths which will achieve repair processing. The repaired results of the damaged blade are analyzed according to the reverse model of non-damaged blade. And the results show that the profile errors are basically within 0.03mm which meet the tolerance requirements of repairing blades and there are smooth transition between repaired and non-repaired areas. The method presented in this paper has a good effect on repairing aero-engine blades.