A method for repairing an airfoil comprising creating a nominal numerically-controlled tool path based on a nominal shape of the airfoil, measuring the airfoil using a displacement sensor, capturing differences in the airfoil shape as compared to the nominal shape, creating a three-dimensional map by synchronizing x, y and z coordinates and readings from the sensor, modifying the tool path based on the three-dimensional map, and machining the airfoil. A system for measuring and machining an airfoil comprising a computer operable for data acquisition and numerically-controlled tool path generation, a numerically-controlled machine, a cutting tool holder comprising a plurality of cutting tools, and a displacement-sensing probe.