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The geometry of each w part is unique, so that a repair has to be tailored to each part individually. To ensure that a high quality repair is carried out, tool paths have to be generated adaptively for the unique geometry and pose of the part being repaired. A polygonal modelling approach is introduced to rapidly construct a geometric model of the part to be repaired, together with a defect-free model with identical geometry and poise. The two models are compared so that the defects are identified for direct use by the laser cladding, machining and inspection processes.