<p>After the additive remanufacturing of damaged blade surface, in process of restoring the shape and size, it still faces the issues of large deformation, complex reverse engineering, and uneven machining allowance distribution. In this paper, an effective trajectory planning method for grinding repaired blades is presented to directly generate the toolpath on the triangular mesh surface by considering the modified feed rate model. Initially, the theoretical model of repaired blade is quickly determined to be the triangular mesh through optical scanning the adjacent blade at the same conditions. The toolpath is generated on the triangular mesh based on the region growing algorithm and the constant arc length interpolation algorithm to eliminate the over-grinding at the large curvature changes. The tool axes are constrained to the normal vector projection of the nearest point and the tangent vector of spline curves to improve the toolpath calculation accuracy. Subsequently, the material removal rate (MRR) model is established by considering the feed rate of grinding tool, and the dwell time of each cutter contact (CC) point is calculated by the truncated singular value decomposition (TSVD) method to reduce the impact of too small singular values on the solving accuracy. Simulation and experimental results demonstrate the effectiveness of the proposed method for robotic grinding repaired blades from the perspectives of machined efficiency and machined quality. The results show that the surface roughness could reach about 0.358 μm, the surface profile error is within 0.091 mm, and there is a smooth geometric transition between repaired and non-repaired areas. Compared to the CNC machining strategy, the presented trajectory planning method provides an effective solution for robotic grinding of complex surfaces with large deformation and uneven machining allowance.</p>