A component or region of an integrally bladed rotor (IBR) includes damage or a defect within a region on the blade of the rotor. A digital representation of the component is generated using an inspection system. The region is identified within the digital representation of the component. Data regarding the scanned IBR is aligned. The aligned data is used in a morphing process with a finite element model of the component that excludes the identified region. Additional operations are performed to morph the data within the identified region that removes the damage or defect from the finite element model.

The method can include mounting the part on a machining fixture, obtaining a geometrical relationship between a machining reference feature of the part and a setup reference feature of the part, such as via a 3D model acquired by scanning, measuring a position and orientation of the setup reference feature relative the machining fixture, computing a position and orientation of the machining reference feature based on the geometrical relationship and on the measured position and orientation; and machining the target feature of the part relative to the computed position and orientation of the machining feature.