Purpose-The aim of the paper is to provide an economically viable solution for the blade repair process. There is a continual increase in the repair market, which requires an increased level of specialised technology to reduce the repair cost and to increase productivity of the process. Design/methodology/approach-This paper introduces the aerospace component defects to be repaired. Current repair technologies including building-up and machining technology are reviewed. Through the analysis of these available technologies, this paper proposes an integrated repair strategy through information integration and processes concentration. Findings-Provides detailed description and discussion for the repair system, including 3D digitising system, repair inspection, reverse engineeringbased polygonal modelling, and adaptive laser cladding and adaptive machining process. Originality/value-This paper describes a 3D non-contact measurement-based repair integration system, and provides a solution to create an individual blade-oriented nominal model to achieve adaptive repair process (laser cladding/machining) and automated inspection.