First article inspection: AS9102 checklist and FAI triggers

A first article inspection catches a misread drawing note or a wrong NC program on one part, before a whole lot is built that way. Teams that know when an FAI is due, and collect the package before the first production order ships, avoid parts they can't use.

What is first article inspection?

First article inspection (FAI) is a complete, independent and documented check of a representative part from the first production run against every design characteristic on its drawing, specifications and purchase order. Aerospace suppliers record it on the three AS9102 forms. It shows that the production process, documentation and tooling can make a conforming part.

SAE published the current revision, AS9102C, on June 28, 2023, and the International Aerospace Quality Group (IAQG) maintains the same standard as 9102 worldwide. It documents the production process verification that AS9100D clause 8.5.1.3 asks for on a new part or assembly.

Rev C applies to each deliverable item separately and removed the exemption for one-off production runs. Rev C lets a detailed certificate of conformance from an external special processor serve as its evidence. IAQG, 9102 summary of changes, Section 1.3.

Selling into the EU?

European aerospace customers apply the same IAQG standard as EN 9102:2024, which ASD-STAN prepared to replace EN 9102:2015; DIN publishes it as DIN EN 9102:2025-01. DIN EN 9102:2025-01. A FAIR on the Rev C forms serves European and US aerospace customers alike. German automotive customers use a different release. VDA Volume 2 calls it Produktionsprozess- und Produktfreigabe (PPF), and the customer and supplier agree its scope. VDA Volume 2, 6th revised edition (April 2020). A 7th edition circulated as a draft (Gelbband) in January 2026, not yet in force. PPF is the automotive counterpart of PPAP, not of AS9102.

What does an FAI prove, and what doesn't it?

An accepted FAI shows that the supplier understood every requirement and that its processes, work instructions and tooling produced one conforming part under production conditions. It does not accept product or cover parts made after a change, and it doesn't prove the process stays capable. Receiving inspection and certificates of conformance still apply to every shipment.

Rev C states outright that an FAI is not a product acceptance document. IAQG, 9102 summary of changes, Section 1.2. One part measured once says nothing about variation across later lots.

In the United States

US government contracts use "first article approval," which is a different thing. Under FAR subpart 9.3, a contracting officer may require first article testing when, for example, the contractor has not supplied the item before or production has been discontinued for an extended period. FAR 9.303. Clause 52.209-3 has the contractor run the tests, and 52.209-4 has the government test delivered units. The contracting officer then approves, conditionally approves or disapproves in writing. A late test report or a disapproval counts as a failure to deliver under the Default clause, and material bought before approval is at the contractor's sole risk. FAR 52.209-3(b), (d) and (g). AS9102 is a supplier's own documented verification that customers flow down through quality clauses, so a defense contract can require both. Agencies adopted the overhauled FAR through class deviations, including DoD's deviation 2026-O0042, so read the clause version in your contract. FAR Overhaul, deviation guide.

What goes on AS9102 Forms 1, 2 and 3?

Form 1 identifies the part and the first article inspection report (FAIR), and lists lower-level parts for an assembly. Form 2 records the materials, special processes and functional tests with their sources and certificates. Form 3 lists every design characteristic with its measured or verified result. Rev C requires the same FAIR identifier on all three forms.

AS9102 forms at a glance

Copy linkDownload image

A four-row table comparing the AS9102 Rev C first article inspection forms. Form 1, part number accountability, identifies the part, drawing revisions, full or partial FAI and lower-level parts. Form 2, product accountability, lists materials, special processes and functional tests with suppliers and certificates. Form 3, characteristic accountability, lists every ballooned design characteristic with its requirement and result. A final row shows that the same FAIR identifier appears on all three forms.

Form	Name	What it records	Key Rev C fields
Form 1	Part number accountability	Part number, name and serial number; part and drawing revisions; manufacturing process reference; detail or assembly FAI; full or partial FAI with baseline and reason; for an assembly, each lower-level part plus unmodified standard catalogue and COTS items	Field 14 full or partial FAI, with a reason for either; field 19 documented nonconformance; field 20 FAIR Verified By; field 22 FAIR Reviewed/Approved By (required); field 24 Customer Approval
Form 2	Product accountability	Raw materials, special processes and functional tests, each with its specification, supplier, and certificate or acceptance report number	Field 8 Supplier; field 9 Customer Approval Verification; field 12 Acceptance Report Number
Form 3	Characteristic accountability	Every design characteristic by characteristic number (often a balloon number), with its requirement, result, designed or qualified tooling, and any nonconformance reference	Field 5 characteristic number; field 8 requirement, including software
All three forms	FAIR identifier	The same identifier links Forms 1, 2 and 3 and the ballooned drawing into one report	Field 4 FAIR Identifier (required)

Form 1, part number accountability, records the part and drawing revisions, a manufacturing process reference that ties the FAI to its router, and whether the FAI is full or partial. Rev C asks for a reason in field 14 for both full and partial FAIs. For an assembly, Form 1 lists each lower-level part with its FAIR identifier, plus unmodified standard catalogue and COTS items. Field 19 records whether the FAIR contains a documented nonconformance. IAQG, 9102 summary of changes, Form 1.

Form 2, product accountability, covers what a dimensional check can't see, such as raw material, special processes like heat treatment or plating, and functional tests. Each line names the specification, the supplier and the certificate or acceptance report number. Field 9 records whether the customer must approve that process or material source.

Form 3, characteristic accountability, gives each design characteristic a number, the requirement, the result and the tooling used. The numbers usually come from a ballooned drawing, where every dimension, note and specification callout carries a numbered balloon that matches one line on Form 3. Rev C added formal definitions for ballooned documents and characteristics, and customers expect the ballooned drawing in the package.

When is a new FAI required?

A full FAI is due on the first production run of a new part. AS9102C then requires a documented evaluation whenever the design, source, process, tooling, material, location or NC program changes, after disruptive events, and after a two-year production lapse. The evaluation decides between a full FAI, a partial one or none.

The FAI is repeated when a change invalidates the original results or isn't represented in them. Rev C lists six events that start the evaluation. AS9102C, Section 4.6(b) and (f).

1. The engineering definition changes a design characteristic.
2. The manufacturing source, process, inspection method, tooling, material or location changes, including a bill of materials change.
3. The NC program changes or moves to another medium.
4. A natural or man-made event could have affected the manufacturing process.
5. Corrective action is needed to complete a previous FAI.
6. Production has lapsed for two years.

A new sub-tier source is a change of manufacturing source, and under Rev C the documented evaluation sets the scope. IAQG's 2015 guidance treated a new special process supplier as needing at least a partial FAI for the processes and characteristics that moved. IAQG, 9102 Rev B FAQ (2015), B8.

The two-year lapse runs from the completion of the last production operation to the actual restart of production, not from your last receipt. The FAI covers the characteristics the inactivity may have affected. AS9102C, Section 4.6(f)(6). Customer quality clauses can set a stricter rule.

When a new FAI is required

Copy linkDownload image

A decision table listing events that can require a new AS9102 first article inspection and the usual scope for each. A new part or a new source needs a full FAI. Design, process, tooling, material, location, sub-tier source and NC program changes need a partial or full FAI based on a documented evaluation. A two-year production lapse needs a partial or full FAI for affected characteristics. A repeat order with no change needs none.

Event	AS9102C reference	Usual scope	What to record
First production run of a new part	Section 1; AS9100D clause 8.5.1.3	Full	Full FAIR on a representative part from the first production run
New or second source for an existing part	Section 4.6(f)(2)	Full in practice, because Section 4.6(b) partial conditions can't be met	Full FAIR from the new source, including its special processors' reports or detailed certificates of conformance
Engineering change to a design characteristic	Section 4.6(f)(1)	Partial for the changed characteristics, or full	Baseline part number, revision and reason in Form 1 field 14
Change of process, inspection method, tooling, material or location, including bill of materials changes	Section 4.6(f)(2)	Partial or full, as the documented evaluation decides	Evaluation record and the affected characteristics
New sub-tier special processor or material source	Section 4.6(f)(2); IAQG Rev B FAQ B8	At least a partial FAI covering the moved processes and characteristics	New Form 2 lines, with customer approval status in field 9
NC program change or translation to another medium	Section 4.6(f)(3)	Partial for the affected characteristics	Program revision and the affected characteristics
Natural or man-made event that could affect the process	Section 4.6(f)(4); IAQG Rev B FAQ B5	Partial or full, or none if recovery procedures show the equipment is unaffected	Evaluation and recovery evidence
Corrective action needed to complete a previous FAI	Section 4.6(f)(5)	Partial for the nonconforming characteristics, on the next production run	Nonconformance reference and new results
Production lapse of two years, from the last production operation to restart	Section 4.6(f)(6); IAQG Rev B FAQ B1	Partial or full for the characteristics the inactivity may affect	Last production date, restart date and the rationale for characteristics not re-inspected
Change evaluated as not invalidating the previous FAI	Section 4.6(f)	None	The documented evaluation
Repeat order from the same source and configuration with no Section 4.6 event	Section 4.6(a)	None	Reference to the existing FAIR

Full or partial FAI?

A partial FAI covers only the characteristics a change affects. It builds on a baseline FAI whose other characteristics conformed and are still made by the original processes. Form 1 records the baseline part number, revision and reason. AS9102C, Section 4.6(b), (d) and (e). The supplier uses Form 1 and only the additional forms required, and the original forms must never be altered. IAQG, 9102 Rev B FAQ (2015), F4. A full FAI may be completed in place of a partial FAI. AS9102C, Section 4.6(b), Note 1.

Who approves an FAI?

The supplier that makes the part performs and approves its own FAI. Form 1 records who verified the FAIR (field 20) and who reviewed and approved it (field 22). The customer approves the FAIR only when the purchase order requires submission, and that decision goes in a separate customer approval field on Form 1.

Rev C made field 22, FAIR Reviewed/Approved By, mandatory, and moved customer approval to field 24. IAQG, 9102 summary of changes, Form 1. Primes set their own submission route and timing in purchase order quality clauses.

How do you run an FAI for a new or second source?

A new or second source gets a new first production run. A partial FAI needs the other characteristics to still come from the original processes, which a new source can't show. The new source performs a full FAI. AS9102C, Section 4.6(b). Plan it, including reports or certificates from special processors, before the first production order ships.

For dual sourcing, build the FAI lead time into the qualification plan. Check Form 2 field 9 early: customers won't accept a FAIR listing an unapproved processor. Line up special process approval first. In an emergency qualification, start FAI planning day one. If the build can't wait, ask the customer in writing how to handle early parts, and check your contract and counsel.

Why do FAI packages get rejected?

A package comes back when it can't prove what it claims. The usual gaps are a characteristic missing from Form 3, forms that disagree on revision or FAIR identifier, a special process without its certificate, and a nonconformance that was reworked but never recorded.

• A result can't be compared with its requirement. IAQG guidance says raw coordinate data can't show a positional tolerance. IAQG, 9102 Rev B FAQ (2015), A8.
• Form 2 lists a specification without its certificate or heat lot, or the sub-tier processor's evidence is missing.
• A nonconformance was reworked to print but not recorded on Form 3 and in Form 1 field 19. AS9102C, Section 4.5. QinetiQ, FAI guide QMS0013033, Section 4.
• A partial FAI doesn't name its baseline or its reason.

How do buyers track open FAIs?

Keep one FAI log keyed by part number, revision, source and manufacturing site. An entry stays open until the FAIR has been reviewed, any required customer approval is recorded, and no nonconformance remains open. Link each entry to the first production purchase order, so nothing ships from a new or changed source without its FAI.

Track the buyer's side with a readiness tracker:

Read each supplier change notice against the Section 4.6 list, and record the last production date for low-volume parts so a restart after two years gets caught. Your team can open each FAI request as a task and hand it to Scout Agent, who follows up with the supplier by email and phone.

Questions teams ask

Do standard hardware and COTS items need their own FAI?

Unmodified standard catalogue and COTS items need no report of their own and are listed on Form 1 of the next-level FAI, and a modified item is listed on Form 2 of the next-level FAI. IAQG, 9102 Rev B FAQ (2015), C1.

Does a repeat order from the same supplier need a new FAI?

A repeat order needs a new FAI only if a Section 4.6 event occurs and the evaluation finds the earlier FAI no longer represents the part, or your customer's clause adds a trigger. Ask the supplier about changes and its last production date before you place the order.

Can the supplier ship before the FAI is complete?

AS9102 doesn't grant that permission, and an FAI with an open nonconformance stays incomplete. Your customer's written agreement and your contract decide whether early parts can ship.

If FAI follow-up from new or changed sources keeps holding up first shipments, talk to our team.

This article is general information, not legal or tax advice. Check how the rules apply to your business with your legal or tax advisor.

Sources (13)

1. SAE AS9102C, Aerospace Series – First Article Inspection Requirements (revised June 28, 2023)
2. SAE Mobilus, AS9102C scope and revision date
3. IAQG, 9102 summary of changes, Rev B to Rev C (July 11, 2023)
4. IAQG, 9102 Rev B FAQ, First Article Inspection 9102B updated FAQs (February 19, 2015)
5. Sonaca NA / LMI Aerospace, AS9102 FAI Standard FAI STD-001 Rev M (June 30, 2025), quoting AS9102C Section 4.6
6. QinetiQ, Supplier Quality Clause M1 FAI Guide QMS0013033 Rev A
7. DIN, DIN EN 9102:2025-01, German and English version of EN 9102:2024 (prepared by ASD-STAN, superseding EN 9102:2015)
8. VDA QMC, VDA Volume 2 Sicherung der Qualität von Lieferungen – PPF, 6th revised edition (April 2020)
9. VDA QMC, VDA Volume 2 PPF, 7th edition Gelbband draft for comment (January 2026) — not current, cited only to flag the draft
10. FAR subpart 9.3, First Article Testing and Approval
11. FAR 52.209-3, First Article Approval—Contractor Testing
12. FAR 52.209-4, First Article Approval—Government Testing
13. Acquisition.gov, FAR Overhaul Part Deviation Guide