A process for repairing an aircraft engine component includes receiving a plurality of component measurements of a damaged component, comparing the plurality of component measurements of the damaged component to a finite element model of an ideal component, generating a finite element model of the damaged component based at least partially on the comparison, determining a corrective material removal operation based at least in part on the finite element model of the damaged component, and removing material from the damaged component according to the corrective material removal operation, thereby creating a repaired component.