First article inspection is the formal, documented proof that the first production part off a new setup meets every requirement on the drawing before the rest of the run continues. In aerospace and defense the governing standard is AS9102, and a completed first article inspection report (FAIR) is often a contractual deliverable, not an option. This guide explains when FAI is required, what the AS9102 forms actually contain, and how it affects cost and lead time.
What first article inspection means
An FAI verifies that a manufacturing process produces conforming parts. It is a validation of the process, not just the part. You prove that the fixtures, the CNC program, the tooling, and the inspection method all combine to produce a part that matches the design. Because it validates the process, an FAI is triggered by change, not only by a first-ever order.
When an AS9102 FAI is required
- The first production run of a new part number
- A change to the design (a revised drawing or model)
- A change in manufacturing source, location, or process (new shop, new machine, new operation)
- A change in material or a material subprocess such as heat treat or plating
- A lapse in production, commonly 2 years or more, per customer requirement
- A prior nonconformance that required corrective action affecting the part
Partial FAI is common. If only one feature changed, you re-verify the affected characteristics rather than the whole part. Your purchase order or quality clause will state whether a full or partial FAI is expected.
The three AS9102 forms
AS9102 (current revision AS9102C) standardizes the report into three forms. A complete FAIR package contains all three plus supporting evidence.
- Form 1, Part Number Accountability. Identifies the part, drawing revision, and any sub-assemblies. It rolls up every detail part into the assembly and confirms nothing is missing.
- Form 2, Product Accountability. Records the raw material, specifications, special processes (heat treat, anodize, passivate), and the certifications behind each. This is where material certs and process certs are tied to the part.
- Form 3, Characteristic Accountability. The heart of the report. Every drawing requirement is ballooned and listed with its design value, tolerance, the actual measured result, and the tool or method used to measure it.
Supporting evidence attached to the FAIR
- A ballooned drawing where each characteristic carries a unique number that matches Form 3
- CMM inspection reports for dimensional characteristics, since a coordinate measuring machine is the standard method for verifying position, profile, and tight tolerances
- Material certifications and, for defense work, evidence of DFARS-compliant material
- Special process certifications from approved sources
- Functional or hardness test results where the print calls them out
How FAI affects cost and lead time
An AS9102 first article inspection report is labor. Someone balloons the drawing, builds the CMM program, measures the part, and fills out three forms with traceable evidence. Budget for it as a distinct line item. The ranges below are typical illustrative estimates for a machined detail part, not binding quotes.
| FAI element | What it involves | Typical range |
|---|---|---|
| Drawing ballooning | Numbering every characteristic and mapping to Form 3 | $75 to $300 |
| CMM programming and layout | Building the program and measuring the first article | $200 to $700 |
| Form 1, 2, 3 completion | Populating the AS9102 forms with traceable data | $150 to $500 |
| Material and process cert gathering | Collecting and tying certs to Form 2 | $40 to $150 |
| Full FAIR package (simple detail) | Complete AS9102C deliverable, low feature count | $400 to $900 |
| Full FAIR package (complex part) | High feature count, multiple processes, tight GD&T | $900 to $2,500 |
On lead time, a first article typically adds 2 to 5 business days beyond the machining schedule because the first good part must be fully documented and, in many flows, customer-approved before the balance of the order runs. Complex parts with special processes can add more when certs must arrive from outside processors.
How to keep FAI cost and schedule under control
- Send the native CAD model and a clean, current-revision drawing. Ambiguous prints slow ballooning and drive back-and-forth.
- State the FAI level clearly on the PO: full, partial, and which forms and evidence you require.
- Confirm whether you need customer approval of the FAIR before production continues, since that gate adds calendar days.
- Ask the shop to reuse the CMM program on repeat orders so the layout cost is not repeated.
FAI and defense work
For government and defense parts, first article inspection frequently pairs with DFARS-compliant material and full traceability. Wexmar is SAM.gov and CAGE registered, sources DFARS material, and performs in-house CMM inspection to support AS9102 documentation. See our government and defense machining and inspection and quality capabilities, and route a print through our instant quote to specify the FAI level you need up front.