Method of manufacture of airfoil castings using autonomous adaptive machining

An airfoil manufacture system, the system comprising:

• a computer numerical control machine configured to machine a contour into a surface of the airfoil;
• a three-dimensional scanning system with a first scanning probe, wherein the first scanning probe is disposed to produce sensor signals in response to scanning a surface of the airfoil with the first scanning probe;
• and
• a controller electrically connected to the computer numerical control machine and to the three-dimensional scanning system, wherein the controller controls operation of the computer numerical control machine and the three-dimensional scanning system, wherein the controller comprises:
• a processor;
• and
• a geometry engine, wherein at least one of the processor and the geometry engine are configured to:
• create a transformation matrix based on data from the probe;
• apply the transformation matrix to a first set of machine toolpath instructions;
• create a transformed set of machine toolpath instructions;
• and
• deliver the transformed set of machine toolpath instructions to the computer numerical control machine.