AS9102 FAI report: how to fill in Form 3
A FAI (First Article Inspection) shows that a manufacturing process produces a part that conforms to the drawing. In aerospace, its format is defined by AS9102, published in Europe as EN 9102.
When is a FAI required?
- The first time a new part number is produced.
- After a drawing change (new revision) affecting characteristics.
- After a change of process, tooling, machine, site or supplier.
- After a production gap of more than two years.
The three forms of the report
- Form 1 — part identification: part number, revision, name, organisation, sign-off.
- Form 2 — materials, special processes (treatments, welding…) and functional tests.
- Form 3 — results: one line per drawing characteristic, with the measured value.
Filling in Form 3, column by column
- Characteristic number: the balloon number on the drawing.
- Location: the drawing zone (for example B3) or the view.
- Requirement: the dimension and its tolerance, as written on the drawing.
- Result: the value measured on the part.
- Conformance: pass or fail, with any deviation.
- Measuring instrument and remarks.
Ballooning: the starting point of a FAI
Every drawing characteristic (dimensions, geometric tolerances, surface finish, notes) gets a number in a balloon. That number is the reference used in Form 3: the customer must be able to find each line on the ballooned drawing, and vice versa.
The most common mistakes
- Missing characteristics: notes, roughness, threads, chamfers.
- Different numbering between the ballooned drawing and Form 3.
- Wrong min and max for dimensions governed by general tolerances.
- Out-of-tolerance results left without justification or concession.
Frequently asked questions
- What is the difference between AS9102 and EN 9102?
- EN 9102 is the European edition of AS9102. The content and forms are the same.
- Is a partial FAI allowed?
- Yes: after a change, only the affected characteristics are verified, referring back to the previous FAI.