/ RESOURCES
What Is First Article Inspection in Aerospace?
FAI is the documented verification that the first part off a new or changed production process conforms to all drawing and specification requirements — before the production lot runs.
/ DEFINITION
FAI — What It Is and What It Does
First Article Inspection (FAI) is a structured, documented verification process performed on the first part produced from a new production process, or after certain changes to an existing process. Its purpose is to verify — before a production run begins — that the production process is capable of consistently producing a conforming part.
FAI is not a substitute for production inspection. It is a pre-production gate check: the machining process, the documentation, the material, and the dimensions are all verified against the drawing and specification requirements on the first article before the shop commits to producing the full quantity.
AS9100D makes FAI a certification requirement for qualifying trigger events. On a program managed under an AS9100D quality system, the FAI is not optional — it is documented and part of the quality record.
/ WHAT TRIGGERS FAI
When an FAI Is Required
AS9100D requires FAI for:
- New part numbers: The first time a part number is produced by a supplier.
- Design changes: A drawing revision change that affects the part — dimensional, material, surface finish, or feature changes.
- Manufacturing process changes: A change to the production process that could affect part conformance — new tooling strategy, different machine, new fixturing, process re-route.
- Production gap reactivation: A part that has not been produced within a defined interval (often 24 months per program requirements) requires FAI before production restarts. The interval may be defined by your purchasing specification.
Individual programs or purchasing specifications may define additional FAI trigger events beyond the AS9100D baseline. Confirm the FAI requirements for your program in the purchasing specification or on the drawing before placing the order.
/ PACKAGE CONTENTS
What Goes Into an FAI Package
Dimensional Inspection Report
Every dimension on the drawing is ballooned, measured, and recorded. The report shows the nominal value, the measured value, the tolerance, and pass/fail status. Critical dimensions are typically CMM-verified. The ballooned drawing is retained as part of the FAI record.
Material Certifications
Mill certifications for the raw material lot used for the first article, traceable to specific heat lot numbers. Certifications verify material composition, mechanical properties, and compliance with the specified material standard (AMS, ASTM, etc.).
Certificate of Conformance
The CoC states that the first article part conforms to the drawing and specification requirements. It references the drawing revision, the material specification, and the purchase order number.
Process Documentation
Setup approval records, in-process inspection checkpoints, and manufacturing traveler documentation from the first article production run. This establishes the baseline production process that the subsequent production lot will replicate.
Special Process Certifications
If the part requires special processes — heat treatment, surface treatment, NDT — certifications from the performing facility are included in the FAI package.
/ FAI VS. FAIR
FAI vs. FAIR — What's the Difference?
FAI (First Article Inspection) is the process. FAIR (First Article Inspection Report) is a specific document format.
AS9102 is the aerospace standard for First Article Inspection Requirements — it defines the format for the FAIR document. A program that requires AS9102 compliance will specify the FAIR form as the required documentation format. A program that requires FAI per AS9100D but doesn't specify AS9102 format may accept the supplier's own dimensional inspection report format.
Confirm the required format before placing the purchase order. Requesting AS9102 FAIR format after the part is shipped is not always satisfiable retroactively.
Request an FAI Package on Your First Order
Specify FAI requirements when you submit your RFQ. We'll confirm scope and include FAI in the program quote.
/ QUOTE RESPONSE — 24HR AFTER SUBMISSION