A balancing technique for casting or forging parts to be machined is presented in this paper. It allows an optimal part setup to make sure that no shortage of material (undercut) will occur during machining. Particularly in the heavy part industry, where the resulting casting size and shape may deviate from expectations, the balancing process discovers whether or not the design model is totally enclosed in the actual part to be machined. The alignment is an iterative process involving nonlinear constrained optimization, which forces data points to lie outside the nominal model under a specific order of priority. Newton methods for non-linear numerical minimization are rarely applied to this problem because of the high cost of computing. In this paper, Newton methods are applied to the balancing of blank part. The aforesaid algorithm is demonstrated in term of a marine propeller blade, and result shows that The Newton methods are more efficient and accurate than those implemented in past research and have distinct advantages compared to the registration methods widely used today.