Numerous technologies are currently available to repair and maintain manufactured parts for the aerospace industry. However, the real challenge comes when the part has been manufactured to tight tolerances and dimensions, when a relatively small Heat Affected Zone (HAZ) is allowable for the repair, or when the part must perform perfectly in a high reliability application. Optomec, Inc., in Albuquerque, NM has developed LENS® (Laser Engineered Net Shaping™) technology, which offers a superior solution to the aerospace repair/overhaul market. LENS offers significant advantages over current systems because of its ability to equal or better the properties of conventional wrought materials, its small HAZ, and a strong ROI. LENS also delivers enormous potential for low volume manufacturing and prototyping applications. The LENS process refurbishes worn or damaged parts directly from the CAD file in a single step. Starting with the CAD information, a computer-controlled laser is focused on a tiny spot on a metal substrate, creating a molten pool on the surface. A nozzle blows a precise amount of metal powder into the molten pool to increase material volume. A layer is built to the CAD geometry as the positioning system moves the substrate under the beam in the XY plane. The lasing and powder deposition process repeats until the layer is complete. The system then refocuses the laser in the Z-direction until the unit builds layer-upon-layer a metal version of the CAD model. A wide range of engineering materials can be used, including titanium, stainless steel, nickel, and cobalt-based superalloys. The mechanical properties of the parts are equivalent to or exceed those obtained from standard techniques, allowing direct use even in the most demanding applications. Current applications include Repair & Overhaul, Rapid Prototyping, Hybrid Manufacturing, Low-Volume Manufacturing, and Advanced Technology Development. This paper will describe the distinct advantages of a LENS repair part for the aerospace industry, and the unique process that Optomec has developed.