Service · Inspection

Verify before scale.
Document fully.
AS9102 / PPAP.

First Article Inspection (FAI) services for aerospace, medical, automotive industries. Comprehensive dimensional verification, GD&T compliance, material certification, full documentation per AS9102 (aerospace) or PPAP (automotive) format.

First Article Inspection Quote Inspection methods

AS9102 format PPAP capability CMM verification Material certified

01 · FAI standards

FAI documentation formats.

Different industries require different FAI formats. We provide documentation in customer-required format with all standard content.

AS9102 (aerospace)

Standard AS9102

Aerospace First Article Inspection per AS9102 Rev C. Form 1 (part identification), Form 2 (product accountability), Form 3 (characteristic accountability). Standard for aerospace tier-2/3 supply chain.

PPAP (automotive)

Production Part Approval Process

Automotive PPAP per AIAG (US) or VDA (European). Levels 1-5 depending on customer. Includes design records, FMEA, control plan, capability studies. Standard for automotive Tier-1 launches.

Custom customer FAI

Per customer format

Some customers (medical, defense) have specific FAI formats. We complete in their template with same underlying inspection rigor.

Dimensional verification

100% all features

First article: 100% inspection of all drawing features. CMM verification of GD&T, calipers/micrometers for standard features, special test for unique requirements.

Material certification

EN 10204 3.1

Material certificates per EN 10204 3.1 — chemistry, mechanical properties, heat number traceability. Sometimes 3.2 (witnessed) for critical applications.

Process records

Heat treat, coatings

Documentation of all process steps: heat treatment certificates, coating certificates (anodize, plating), special process records.

Statistical process

Cpk for production

For production parts after FAI, statistical process control with Cpk targets. First article shows process capability for ongoing production.

Customer signoff

Approval before production

Customer reviews and signs off FAI before production release. Production halted until approval.

Revisions handled

Revision-controlled FAIs

Drawing revision changes trigger updated FAI. Customer notified of revision FAI before production change.

02 · FAI process

FAI workflow.

Drawing review

Drawing reviewed for clarity, GD&T interpretation

CMM programming

First-article CMM program developed (1-3 hours typical)

Material certification

Material certificate sourced from supplier

Manufacturing

First article produced per drawing using documented process

Dimensional measurement

100% feature inspection vs drawing tolerance

Process documentation

Heat treat, coating, special process certs collected

Report assembly

FAI report assembled in customer format

Internal review

Internal QA review before customer submittal

Customer submission

Submitted to customer with cover letter

FAQ

First Article Inspection questions.

AS9102 Rev C content: (1) Form 1 — part identification (number, name, revision, supplier). (2) Form 2 — product accountability (drawing notes, special characteristics, materials). (3) Form 3 — characteristic accountability (every feature with nominal, tolerance, actual). Plus attached: material certifications, special process certs, dimensional inspection records, photos. Typical AS9102 package: 10-40 pages depending on part complexity.

PPAP Level 1: warrant only. Rare for new programs. Level 2: warrant + samples + limited docs. Level 3: most common — warrant + samples + complete documentation package. Level 4: as Level 3 plus customer-specific requirements. Level 5: as Level 4 plus parts and complete supporting data retained at supplier. Customer specifies — typically Level 3 for production launch.

For typical FAI, CMM repeatability ±0.002 mm adequate. Calibration traceable to NIST. Specific high-precision applications (aerospace, semiconductor) may require ±0.001 mm — partner with calibration labs for ultra-precision measurements. Most production CMM work meets standard accuracy requirements with documented calibration.

Simple part FAI (10-20 features): 1-2 days for measurement + 2-3 days documentation. Complex part FAI (50+ features with extensive GD&T): 5-10 days total. Aerospace AS9102 with full documentation: 7-14 days typical. Plan FAI timing into project schedule — production gate typically requires customer FAI approval.

Drawing revision triggers re-inspection — features changed by revision require new measurement. Some customers require complete FAI on every revision; others only on significant changes. Specify customer policy upfront. We track revision changes and re-inspect appropriately.

AS9102 records retained 10+ years per FAR. Aerospace customers often require 25+ year retention. Medical: full product life + 2 years per FDA. Automotive: 15 years per IATF 16949. Our standard archive policy: 10+ years for all quality-controlled orders, longer per customer requirement.