Abstract: A method for fabricating a component using a tool is provided. The method includes determining a model tool contact path for the component based on a component geometry, nominal tool tip path, tool geometry, the component geometry including a grid system having a plurality of elements and nodes at an intersection of the elements. The method also includes measuring a geometric property of the component relative to the model component geometry, generating a tool contact path and tool tip path corresponding to the measured geometric property, and at least partially fabricating the component using the generated tool contact path.

Abstract: A method for fabricating a component using a tool includes determining an actual property of a region of the component, comparing the actual property of the region of the component with an expected property of the region to determine a difference between the actual property and the expected property, and updating a path of the tool that is electronically stored in a memory and executable by a processor for fabricating the component based on the difference between the actual property and the expected property of the region.

Abstract: An integrated compressor disk and compressor blade (BLISK) having a specified shape is prepared by an electrochemical machining process having a cathode defined by a set of cathode shape parameters. A trial BLISK is prepared using a cathode defined by a set of trial shape parameters, and a set of deviations of the trial shape from the specified shape at a plurality of surface grid points on a surface of the trial article is measured. A set of revised cathode shape parameters is determined using at least one reshaping routine specific to the BLISK. A reshaped article is prepared using the electrochemical machining process and a reshaped cathode defined by the revised cathode shape parameters.