With hybrid manufacturing maturing into a commercial scale, industries are pushing to integrate and fully utilize this new technology in their production facilities. Using the capability to interleave additive and subtractive manufacturing, these systems provide an opportunity to perform component repair through additive material deposition and resurfacing via machining. This is particularly attractive to industries which utilize complex, often freeform, components which require a large capital investment, such as the aerospace and mold and die industries. However, in service these components may experience unique distortions or wear, and therefore each require a unique repair strategy. This work seeks to create an adaptive transformation method for part geometry, which can adapt the process to match the needs of an individual component within the context of a commercial hybrid manufacturing system using currently available on machine inspection technology; greatly improving the efficiency of repair processes. To accomplish this, a new methodology for the adaptation of a nominal CAD geometry to a component is presented which combines data registration and reverse engineering strategies for aero engine components. The accuracy of this deformation method is first examined, then simulations are completed to explore the potential efficiency gains in both the additive and subtractive phases of a hybrid repair process.M.S
