What is First Article Inspection (FAI)?

Before committing to mass production, companies need a way to validate that everything is set up correctly. That’s where First Article Inspection (FAI) comes in. FAI is the milestone that ensures the first part of the assembly line matches design specifications and quality requirements. 

While prototyping and engineering builds help refine a product, FAI is part of the final validation process. It typically happens during the PVT (Production Validation Test) stage when your contract manufacturer is using production-intent tools and materials.

In this post, we’ll break down when FAI occurs, what its goal is, and how it’s documented to ensure quality and alignment before ramping up to full-scale production.

When Does First Article Inspection Occur?

FAI typically takes place during PVT or the pilot run, which is the first time production is carried out using final tooling, materials, and manufacturing processes. At this stage, your supplier is no longer relying on prototypes or prototyping methods but instead producing parts like they would during mass production. 

For plastic injection molding, FAI is usually done on parts after the T0 or T1 trial. These initial parts provide the first true indication of how well the design translates into a repeatable manufacturing process. The FAI verifies that the tooling is functioning correctly and that the part meets the required specifications before giving the green light to move forward.

By conducting FAI at this point, manufacturers can catch issues early, make tooling adjustments if needed, and ensure that full production won't be based on incorrect assumptions or flawed outputs.

What is the Goal of First Article Inspection?

The primary goal of FAI is to verify that the initial production parts meet all design, engineering, and quality requirements. It’s a formal validation step that confirms whether the supplier can consistently manufacture parts that align with your specifications using production-intent tooling and processes.

This inspection is not just about checking one part, it’s about ensuring that the entire manufacturing setup is ready for scale. That includes validating dimensions, materials, surface finishes, and other critical attributes. If any defects are found, this is the point to make corrective actions. These corrective actions can be made to improve tooling, refining processes, or improving SOPs.

By completing an FAI before full production, you reduce the risk of costly quality issues, rework, or delays. It gives both the customer and the manufacturer confidence that production can proceed without surprises.

How to Document the First Article Inspection

FAI is typically documented through a first article inspection report. This report provides a detailed breakdown of how the inspected part compares to the engineering specifications. It serves as an official record that the supplier has successfully produced a part that meets all requirements.

A well-prepared report usually includes:

• Part number and revision level

• Customer name and project information

• Reference drawings or CAD files

• A ballooned drawing, where each dimension or spec is numbered for easy reference

• A measurement table, listing the required dimensions, tolerances, and the actual measured values

• Material certifications and surface finish results, if applicable

• Photos of the inspected part, especially for visual features or cosmetic requirements

• inspector's name and date of inspection

Depending on the complexity of the part, suppliers may use hand tools like calipers or more advanced equipment like coordinate measuring machines (CMMs) to gather the required data.

Once completed, the report is typically reviewed and signed off by both the supplier and the customer. It becomes a shared reference point to confirm that the production setup is ready to move forward or to document any corrective actions needed before mass production begins.

Why First Article Inspection is a Critical Step

FAI plays a crucial role in bridging the gap between development and mass production. It’s the point where assumptions end and measurable performance begins. Without a formal FAI, it’s easy to overlook dimensional errors, misinterpreted tolerances, or manufacturing defects that could scale into bigger issues once full production starts.

FAI helps ensure that the production line, tooling, and assembly process are all capable of consistently producing parts to spec. It reduces the risk of defective parts reaching your customers and minimizes costly rework or delays down the line.

Just as importantly, FAI creates alignment. It gives your engineering and quality teams a chance to confirm that the supplier understands your expectations and can meet them. For contract manufacturers, it also sets a benchmark: the inspected part becomes a reference for quality control throughout production.

In short, FAI is not just a checkbox; it’s a quality control tool that protects your product, timeline, and reputation.

Conclusion

FAI is a key validation step that confirms your supplier is ready for mass production. By inspecting the first part made from final tooling and documenting it through a formal FAI report, you ensure that your product meets all dimensional, material, and quality requirements before scaling up.

It’s not just about verifying a single part, it’s about verifying the entire manufacturing process. FAI gives both you and your supplier confidence that the production line is dialed in and capable of consistently delivering parts to spec.

If you're preparing for a pilot run or need help setting up a proper FAI process, our team at EPower Corp is here to support you.