Additive manufacturing system and methods for repairing components

An additive repair system (50) for repairing one or more components (70), the additive repair system (50) comprising:

• a tooling assembly (52) for securing the one or more components (70), each of the one or more components (70) having a repair surface (72);
• a vision system (56) for determining a repair toolpath (76) associated with each of the one or more components (70) within the build plane (82);
• a powder dispensing assembly (112) for depositing a layer of additive powder (72) over the repair surface (72) of each of the one or more components (70);
• and
• an energy source (120) for selectively irradiating the layer of additive powder (72) along the repair toolpath (76) to fuse the layer of additive powder (72) onto the repair surface (72) of each of the one or more components (70).