This article introduces a novel model reconstruction method for machining turbine blades damaged in service and repaired via additive manufacturing (AM). Addressing the lack of a model for damaged parts crucial for precise adaptive machining, the method involves model registration and construction. Initially, the AM-repaired blade is aligned with a theoretical CAD model through rough registration using Principal Component Analysis (PCA), followed by precise alignment within the blade profile’s tolerance zone. The model construction employs the minimum curve energy principle to ensure seamless integration with undamaged areas and adherence to profile tolerance constraints. The interfacial profile curve between the undamaged and AM-repaired areas is used as the original curve to construct the curves in the AM-repaired area. The reconstructed curves are modified with a double constraint of being smooth and minimum occupation of the theoretical model tolerance zone. The efficacy of this method is validated through a case study. The repaired blade showed deviations from −0.101 mm to 0.115 mm, within profile tolerances, and a surface smoothness difference of less than 6.41 μm between the damaged and undamaged sections. This method significantly improves the precision and efficiency of turbine blade repair, offering substantial benefits for the turbomachinery manufacturing industry.