First Article Inspection (AS9102): When It's Required and How the Three Forms Work

First Article Inspection (FAI) is how an aerospace supplier proves that its production process can make a part that meets every requirement on the drawing and purchase order. AS9102, currently at Revision C, is the aerospace standard that defines how to plan, perform, and document it — and AS9100 points to FAI as a way to verify production processes.

The FAI is performed on a part representative of the first production run, made with the production process, tooling, and people — not a prototype built by hand.

When an FAI Is Required

• A new part going into production for the first time
• A design change that affects fit, form, or function
• A change in manufacturing source, process, inspection method, location of manufacture, tooling, or material that could affect fit, form, or function
• A change to a numerical control (NC) program, or its translation to another medium, that could affect fit, form, or function
• A natural or man-made event that may have affected the manufacturing process
• A lapse in production of two years, unless your customer specifies a different period

Full or Partial FAI?

A new part needs a full FAI. After a change, a partial FAI that covers only the characteristics the change could affect may be enough — but you have to document the reason on Form 1, and your customer may need to approve it. Your FAI procedure should explain how you decide between the two.

The Three AS9102 Forms

• Form 1 — Part Number Accountability: identifies the part, its sub-assemblies or detail parts, and whether the FAI is full or partial
• Form 2 — Product Accountability: raw materials, specifications, special processes, and functional testing, with the sources and certifications behind them
• Form 3 — Characteristic Accountability, Verification and Compatibility Evaluation: every design characteristic, with the requirement, the actual result, and how it was verified

Most suppliers "balloon" the drawing — number every characteristic — so each Form 3 line traces back to a single spot on the print.

Where NDT and Special Processes Fit

If the drawing or specification calls for NDT, heat treatment, plating, or welding, those processes are recorded on Form 2, with the specification, the processor, and the certification. Aerospace customers often require special processes to be done by approved or NADCAP-accredited sources, so check the purchase order before you choose a processor.

Where Lion NDT fits in. We help aerospace manufacturers write their FAI procedures, review FAI packages against AS9102 before they go to the customer, and confirm that the NDT and special-process records behind Form 2 are complete — and we perform the NDT the drawing calls for, using UT, MT, PT, ET, or VT.