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Laser direct deposition provides an attractive and cost effective means for repairing or remanufacturing high value engineering components. This study demonstrates the successful repair of defective voids in turbine airfoils based on a new semi-automated geometric reconstruction algorithm and a laser direct deposition process. A Boolean difference between the original defective model and the final reconstructed model yields a parameterized geometric representation of the repair volume. The experimental results of this method demonstrate the effectiveness of laser direct deposition in remanufacturing and its potential to adapt to a wide range of part defects. A Life Cycle Assessment (LCA) on the energy and environmental impacts by remanufacturing is also presented.