Reference
First article inspection (FAI): AS9102 and EN 9102 explained
A first article inspection proves, characteristic by characteristic, that the first part made by a new or changed production process matches the drawing – and documents it so that someone else can check. In aerospace the requirements are set by AS9102 and its European twin EN 9102. Here is what they cover, the three forms, and how FAI compares with the PPAP and VDA 2 approvals of the automotive industry.
What a first article inspection is
The first part off a new process is the one where everything that can be wrong still is: the program, the fixture, the tool offsets, the reading of the drawing. A first article inspection measures and records every design characteristic of that part – every dimension, note and specification – and shows for each one whether it was met. It is not a sample check of a few critical sizes; it is the complete account of the drawing.
The result is the first article inspection report (FAIR). Its value lies in being complete and traceable: each requirement on the drawing has a number, and the report has a result for each number.
AS9102 and EN 9102
- SAE AS9102C (28 June 2023, 22 pages) is the current edition in the Americas. Its stated purpose is to establish the requirements for performing and documenting FAI.
- EN 9102:2024 is the European edition; in Germany it is published as DIN EN 9102:2025-01 in German and English, prepared by ASD-STAN.
- Both say the same about their place: the requirements complement those of the customer and of law and regulation – they do not replace them. What your purchase order and your customer's quality clauses say comes on top.
The published table of contents shows how EN 9102 is organised: planning the first article inspection, part requirements, requirements for a digital product definition, evaluation activities, handling of nonconformances, partial or complete re-accomplishment of an FAI, documentation (forms, characteristic accountability, recording results) and retention of documented information. The forms are in a normative annex.
The three forms
The FAI report is made of three forms. Their titles, as the standard names them:
| Form | Title | In plain words |
|---|---|---|
| 1 | Part number accountability | which part, which drawing revision, which assembly it belongs to – the identity of the first article |
| 2 | Product accountability – materials, special processes and functional testing | the evidence behind the part: material, special processes such as heat treatment or plating, functional tests |
| 3 | Characteristic accountability, verification and compatibility evaluation | every design characteristic with its requirement and the result – the dimensional heart of the report |
The blank forms and the instructions for each field are in the standard (annex B of EN 9102); many customers also publish their own versions. We do not reproduce them here.
Preparing an FAI: what works in practice
This is shop practice, not text from the standard:
- Balloon the drawing first. Give every characteristic a number on the drawing – dimensions, tolerances, notes, surface finish, geometric tolerances. The numbers are the backbone of Form 3; a characteristic without a number is a characteristic nobody will report.
- Resolve every tolerance into limits before measuring: »Ø20 H7« becomes 20.000 / 20.021 (see the ISO 286 charts), dimensions without tolerance take the general tolerance of the title block (see ISO 2768).
- Choose a gauge that can see the characteristic. A caliper does not measure position at MMC or cylindricity; the GD&T symbols page lists what each geometric tolerance needs.
- Record actual values, not ticks. »OK« is not a result; 20.012 is.
- Collect the certificates for material and special processes before the part ships, not after the customer asks.
FAI, PPAP and VDA 2: the same goal, three cuts
| FAI (AS9102 / EN 9102) | PPAP (AIAG) | PPF (VDA volume 2) | |
|---|---|---|---|
| Industry | aerospace and defence | automotive, North American OEMs and their chains | automotive, German OEMs and their suppliers |
| Core document | FAI report, three forms | package of 18 elements, warrant (PSW) | Erstmusterprüfbericht (EMPB) with cover sheet |
| How much is sent | set by the customer | levels 1 to 5 | Vorlagestufen (submission levels) |
| Dimensional part | Form 3, every characteristic | element 9, dimensional results | the EMPB itself |
If you supply both industries, the dimensional work is the same: a ballooned drawing and a measured value for every number. What changes is the paperwork around it. PPAP is explained in What is PPAP? and PPAP levels 1 to 5.
Frequently asked questions
What is the difference between AS9102 and EN 9102?
They are the same requirement published in two regions: AS9102 by SAE for the Americas, EN 9102 by ASD-STAN for Europe (in Germany as DIN EN 9102). Use the one your contract names, in the edition it names.
What are the three FAI forms?
Form 1, part number accountability; Form 2, product accountability – materials, special processes and functional testing; Form 3, characteristic accountability, verification and compatibility evaluation.
When does an FAI have to be repeated?
The standard has its own section on partial or complete re-accomplishment of an FAI, and customers usually add their own rules. Check both before you change a drawing revision, a process, a machine or a location.
Sources and date
- SAE AS9102C:2023-06-28, »Aerospace Series – First Article Inspection Requirements«, 22 pages, current – entry at DIN Media, read 30.10.2026.
- DIN EN 9102:2025-01, »Aerospace series – Quality systems – First article inspection requirements«, German and English version EN 9102:2024 – entry at DIN Media and its published table of contents, read 30.10.2026.
The standards are copyrighted and sold by their publishers. This page describes them in our own words from the sources above; the binding text is the standard in the edition your customer requires.