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The service performance and life of the aero-engine are directly affected by the blade machining accuracy. In the end milling of the flexible blade, the profile tolerance would usually be violated by the deflection errors induced by excessive static deformations under the action of milling force. In order to predict the blade deflection errors, this paper presents an iterative algorithm considering the coupling relationship between milling force and elastic deformation based on the milling finite element simulation model. Then a novel multipoint rod-shaped auxiliary support technology is proposed to suppress the blade deflection errors. Taking the influence of layout parameters on blade deflection errors into account, the layout of auxiliary support is optimized by a genetic algorithm. To verify the effectiveness of the proposed method, an auxiliary support mechanism is designed and manufactured, and the deflection errors suppression experiment is implemented. The measured results show that the prediction error of blade maximum deflection is 17.6%. Furthermore, the blade average deflection error on two measured curves reduces from 45.88 μm to 24.39 μm with the support of the designed mechanism. Thus, this auxiliary support mechanism and layout optimization method can achieve higher accuracy in blade milling. [ABSTRACT FROM AUTHOR]