The direct metal forming remanufacture system based on the arc welding and the reverse engineering technique is researched. A broken parts rapid recovery method combined reverse engineering and green remanufacture forming technology is proposed. The intact product and the damaged product should be measured separately, and compare the two groups of measured data to determine the accurate data of repair parts. So the damage position is definite accurately and the 3D model of the damage position is reconstructed by reverse engineering. According to the materials of repair parts and powder materials, the technological parameters are setting, the repair working scheme is proposed and the NC programs are prepared. And then the restoration and direct metal forming is carried out. The problem of accurate positioning during the direct metal forming is solved. The experimental results show that this method can repair the damaged parts accurately.