High value aerospace gas turbine blades are subjected to extreme temperatures during operation, resulting in wear, deformation & distortion over time. After ~30,000 hours of air time, engines are entirely overhauled, the blades are taken out & repaired using manual weld deposition then refinished. Major problems have been identified through errors in the weld build-up process. Half of all blades are reclaimable through remanufacturing but high heat input during welding & poor practice renders many scrap. This industrial research project will proivde a fully automated solution that can identify both wear on the blade and carrries out repairs potentially doubling existing service life. From application of novel techniques and techology made in the UK, increased production throughput and data will allow manufacturers to see benefits such as increased service life, optimised blade design and increased efficiency.