The present paper characterizes the difference between metals and composite repairs in aerospace application. The main difference, focus on 5 axis scarfing instead of 2 axis sheet metal cutting, using a ball nose tool in comparison to a Torus type end mil. Even high feed / low speed strategy comes out to a better surface finish and longer tool life. Using the higher step over on special typed end mills, this increases the tool life and consequently, lowers the cost per part. The new strategy and process understanding leads to more economic in onsite and out site repair solutions.