What Is FAI (First Article Inspection) and How Does AS9102 Rev B Define It?

First Article Inspection (FAI) is a systematic, evidence-based verification process used in manufacturing to confirm that a production process can consistently produce parts that meet all engineering and design requirements. In the aerospace sector, FAI is governed by the international standard AS9102 Rev B (Aerospace First Article Inspection Requirement), which replaces earlier revisions and harmonizes with the global aerospace quality management system AS9100.

This article explains what FAI is, how AS9102 structures it, and how you can apply it effectively—with a clear, illustrative example.

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What It Is

FAI is not a random sample check. It is a complete, documented inspection of the first production run of a new part, a changed part, or a part manufactured after a significant process change. The goal is to verify that all engineering requirements—materials, dimensions, special processes, and functional tests—are met before full-rate production begins.

AS9102 Rev B defines the FAI process and mandates the use of a standardized FAIR (First Article Inspection Report). The report is divided into three parts:

• Part 1 – Product Accountability: Lists the part number, revision level, purchase order, and all sub-tier part numbers. It also records the overall drawing number and the FAI status.
• Part 2 – Product Accountability (Characteristic Verification): Documents each characteristic (dimension, material, process, etc.) with its specification, actual measured value, and the result (pass/fail). This is where the balloon drawing is referenced—each numbered balloon on the drawing corresponds to a row in Part 2.
• Part 3 – Characteristic Accountability (Process & Material): Records special processes (e.g., heat treat, anodize), raw material certifications, and any supplier or sub-tier FAI results. It also lists the characteristics accountability—who is responsible for verifying each requirement.

AS9102 Rev B emphasizes one characteristic, one source of truth: every requirement must be traceable to a drawing note, a model, or a specification, and each must be verified with objective evidence.

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How It Works / Formula or Steps

The FAI process under AS9102 follows a logical sequence:

1. Prepare the balloon drawing.

Print or digitally mark the engineering drawing (or CAD model) and assign a unique balloon number to every characteristic that must be verified. This includes dimensions, tolerances, surface finish, material notes, and process callouts.

1. Complete Part 1 – Product Accountability.

Fill in the part identity, revision, and the full list of sub-components. If you are using sub-tier suppliers, their FAI results must be referenced here.

1. Complete Part 2 – Characteristic Verification.

For each balloon number, record:
- The characteristic description (e.g., "Ø 12.5 ± 0.1 mm").
- The design specification (from the drawing).
- The actual measured value (from your inspection equipment).
- The result: conforming or nonconforming.
- The inspection method and equipment used.

1. Complete Part 3 – Process and Material Accountability.

List all special processes (e.g., "per AMS 2770 heat treatment") and attach certificates of conformance. For each raw material, attach the mill test report. If a characteristic is verified by a supplier, that supplier’s FAI must be included.

1. Review and approve.

A designated quality engineer reviews the FAIR for completeness and accuracy. Any nonconformance must be dispositioned (e.g., rework, use-as-is with customer approval) before the FAI can be closed.

1. Maintain records.

AS9102 requires FAI records to be retained for the life of the part (or as contractually agreed). Any change to the part, process, tooling, or supplier triggers a partial or full re-FAI.

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A Worked Illustrative Example

Example data (illustrative only):

Part: Bracket, P/N 12345, Rev C. Drawing calls out 8 dimensions, 1 special process (anodize per MIL-A-8625), and material 6061-T6 aluminum.

Step 1 – Balloon drawing:
You place balloons 1 through 8 on the dimensions, balloon 9 on the material note, and balloon 10 on the anodize callout.

Step 2 – Part 2 (excerpt):

Balloon | Characteristic | Spec | Actual | Result

• 1 | Hole Ø 6.0 ± 0.1 | 5.9–6.1 | 6.02 | Pass
• 2 | Slot width 10.0 ± 0.2 | 9.8–10.2 | 10.05 | Pass
• ... | ... | ... | ... | ...
• 9 | Material 6061-T6 | per AMS QQ-A-250/11 | Mill cert #M-8821 | Pass

Step 3 – Part 3:
You attach the anodize certificate (balloon 10) and the mill test report (balloon 9). Both are from approved suppliers.

Step 4 – Approval:
All 10 characteristics pass. The FAIR is signed by the quality engineer and released. Production can begin.

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Common Pitfalls

• Incomplete ballooning: Missing a characteristic on the drawing leads to an incomplete FAIR and potential escape.
• Using supplier data without verification: If a sub-tier supplier performs a special process, you must include their FAI or certificate—not just a verbal confirmation.
• Mixing revisions: If the drawing revision changes, a full re-FAI is required, not just a delta check.
• Ignoring "characteristics accountability": AS9102 requires you to identify who is responsible for each characteristic. If this is unclear, the FAIR is not compliant.

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Closing

A robust FAI process built on AS9102 Rev B not only satisfies aerospace customers but also reduces production risk and scrap. To streamline the paperwork and avoid common errors, use a structured digital tool that guides you through Parts 1, 2, and 3, and automatically links your balloon drawing to the verification records. Start your next FAI with a free, ready-to-use template at https://www.6sq.com/tools/fai/ and bring your first article inspection under control.