The dimensional variability and complex shapes found in gas turbine components pose challenges for conventional automated machining. One solution is adaptive machining, where a toolpath unique to each component is generated using digitised data.

Surprisingly, the manufacture and repair of gas turbine blades is still largely being carried out in the traditional way, by people wearing leather gloves and hand-held grinding, finishing and polishing devices.

The problem lies with the fact that individual blades and vanes that make up full engine-sets are not geometrically identical and therefore are not completely interchangeable. While the more crucial dimensions are tied down .