First Article Inspection: What It Is and Why It Matters Before Production
Before a production run starts, someone needs to verify that the first part made actually matches the engineering drawing — not just visually, but dimensionally and materially. That’s what first article inspection is. A first article inspection (FAI) is a formal, documented process that confirms a manufactured part meets all engineering requirements before full production begins. It’s the checkpoint between “we can make this” and “we should make a thousand of these.”
What does a first article inspection actually measure?
An FAI isn’t a pass/fail eyeball check. It’s a systematic dimensional and material review, typically documented in a First Article Inspection Report (FAIR). Depending on the industry and the part, an FAI typically covers:
- All critical and significant dimensions from the engineering drawing, measured and recorded with actual values
- Geometric tolerances — GD&T callouts verified against drawing requirements
- Surface finish measured and compared against specification
- Material certification — confirmation that the material used matches the specified alloy, grade, or formulation
- Process documentation — records of how the part was made, including any special processes like heat treatment or surface coating
- Functional testing where called out on the drawing
Our metrology and inspection team uses calibrated CMM equipment, optical comparators, and contact measurement tools to produce FAI reports that document every measured dimension against its drawing requirement.
What happens if a part fails FAI?
A failed FAI doesn’t mean a scrapped project — it means a documented deviation that needs to be resolved before production proceeds. The typical path looks like this:
First, the failed dimensions are identified and root-causes are investigated. Is the deviation in the machining process, the material, the fixturing, or the drawing itself? Sometimes drawings have errors that only become apparent when someone actually tries to make the part.
Next, corrections are made — either to the manufacturing process or, if a drawing error is identified, through a formal Engineering Change Order (ECO). The corrected part is then re-inspected. The FAI is only closed when all requirements are met and documented.
The cost of catching a problem at FAI is a fraction of the cost of catching it after 500 parts have been made. That’s the economic argument for FAI even when it isn’t contractually required.
When is FAI required — and when is it just good practice?
In aerospace, defense, and medical device manufacturing, FAI is not optional. AS9102 (the aerospace standard) and equivalent medical and defense standards require documented FAI for new parts, modified designs, and parts that have been out of production for a defined period. Customers in these industries will ask for the FAIR before they accept parts.
Outside regulated industries, FAI is a best practice that most experienced manufacturers follow regardless — especially for complex parts, tight-tolerance assemblies, or anything where a production failure would be expensive to sort out. If you’re sourcing parts from a new supplier for the first time, requesting an FAI is a reasonable ask.
The situations where FAI is especially critical:
- New part introduction — first time a design has been made
- Supplier change — same drawing, different manufacturer
- Design revision — even minor ECOs can affect fit and function
- Process change at the manufacturer — new tooling, new machine, new operator
- Production restart after a gap of more than 12–24 months
FAI vs. incoming inspection: what’s the difference?
Incoming inspection checks parts as they arrive — typically a sample from each shipment, verified against critical dimensions. It’s ongoing quality control. FAI is a one-time qualification event that happens before production begins and documents the capability of the manufacturing process to produce a conforming part. They serve different purposes and both have a place in a quality system.
Need an FAI on an upcoming production run?
Whether you need a full AS9102 FAIR or a dimensional report to give your customer confidence before they approve production, Kemperle’s metrology and inspection team can help. We work with manufacturers across industries and have the equipment and documentation processes to produce reports that meet your customer’s requirements.
For a broader look at where first article inspection sits within the discipline of measurement and quality verification, our explainer on what metrology is and why it matters provides useful context.
Contact us to discuss your inspection needs.
For clients in the region, Kemperle Industries also provides services to those seeking first article inspection for Maryland manufacturers, and precision inspection in New Hampshire.
