AS9102 First Article Inspection Report (FAIR) Template with Sample
A first article inspection report, or FAIR, proves that a production process can make a part that meets every drawing and specification requirement. This template gives you the three AS9102 forms with a filled sample, so you can see how a real report reads and then replace the values with your own.
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AS9102 First Article Inspection Report (FAIR) Template
AS9102 First Article Inspection Report
Manufacturer: Acme Precision Machining Ltd Supplier / CAGE code: 1ABC2 FAI report number: FAI-2026-0147 Report date: 2026-10-20 Prepared by: J. Alvarez, Quality Engineer
Form 1: Part Number Accountability
| Field | Entry |
|---|---|
| Part number | BRK-48213-01 |
| Part name | Actuator Mounting Bracket |
| Serial or lot number | LOT 26-0912 |
| Part revision level | C |
| Drawing number and revision | DWG-48213 Rev C, Sheet 1 of 2 |
| Purchase order number | PO-770145 |
| FAI type | Full FAI |
| Reason for FAI | New part number |
| Manufacturing process reference | Routing RT-48213 Rev B |
| Assembly or detail part | Detail part |
| Nonconformance documented | None |
Form 2: Product Accountability (Materials, Special Processes, Functional Testing)
| Item | Specification or detail | Result |
|---|---|---|
| Raw material | Aluminum 7075-T651 plate per AMS 4045, heat lot HL-55871 | Certificate reviewed, conforms |
| Special process | Anodize Type II, Class 2 per MIL-A-8625, supplier: Coastline Finishing (Nadcap accredited); cert CC-9931 | Certificate reviewed, conforms |
| Functional testing | Fit check to mating actuator housing FIX-102: pass. Leak test not applicable. | See notes |
Form 3: Characteristic Accountability, Verification and Compatibility Evaluation
| Char No. | Requirement, result and gauge | Tooling type | Accept / Reject |
|---|---|---|---|
| 1 | Overall length, 120.00 +/- 0.10 mm | Result: 120.04 | Gauge: caliper CAL-0231 | Inspection | Accept |
| 2 | Bore diameter, 25.00 +0.02/-0.00 mm | Result: 25.012 | Gauge: bore gauge CAL-0418 | Inspection | Accept |
| 3 | Surface finish, Ra 1.6 max | Result: Ra 1.1 | Gauge: profilometer CAL-0502 | Inspection | Accept |
| 4 | Hole position, 0.15 true position | Result: 0.09 | Gauge: CMM CAL-0007 | Inspection | Accept |
| 5 | Anodize Type II per specification | Result: certificate reviewed, conforms | Gauge: n/a | Document review | Accept |
| 6 | |||
| 7 | |||
| 8 |
Notes and Review
Every drawing characteristic is ballooned and numbered on the drawing, and each balloon number appears once on Form 3. Include a copy of the ballooned drawing, the material and special process certificates, and the gauge calibration references with the report.
Approval
This template follows the structure of AS9102 (Form 1 part number accountability, Form 2 product accountability, Form 3 characteristic accountability) and is not the official form. The sample is fictional. Check your customer's requirements, because many require their own form version or additional fields such as sampling or key characteristics. Add rows to Form 3 until every ballooned characteristic on the drawing is listed.
Assemble FAI packages from ERP data
Optional: an expert review of how drawings, gauge records, and material certificates in your systems could be gathered into FAI packages automatically.
Optional. The tool and every export work without this. No spam.
How to use the template
Change the sample values in the fields to your part. Form 1 identifies the part and the reason for the FAI. Form 2 records raw materials, special processes, and functional tests with their specifications and certificates. Form 3 lists every characteristic from the drawing, balloon by balloon, with the requirement, the measured result, the gauge used, and accept or reject. Preview the output, then export it to Word, PDF, or Excel and attach the ballooned drawing and certificates.
- Balloon every characteristic on the drawing, including notes and referenced specifications
- Report actual measured values, not just pass
- Identify the gauge and its calibration reference
- Use the production process, tooling, and operators for the FAI part
What the three forms record
Form 1, part number accountability, identifies the part, drawing, and revision, the purchase order, the type of FAI (full or partial), and the reason. Form 2, product accountability, shows the raw material, the special processes, and the functional tests, with the specifications and the certificates that prove them. Form 3, characteristic accountability, shows that each drawing requirement was verified and compatible with the design. Together they give a customer one package that connects the part to its evidence.
Reading the sample
The sample is a machined aluminum bracket. Characteristics 1 to 4 are dimensional with measured values and a gauge, and each is within its tolerance, so each is accepted. Characteristic 5 is a note requiring anodize, verified by reviewing the process certificate. A real report for a part like this typically has many more characteristics, often 20 to 100 or more, so extend the table. If any characteristic is out of tolerance, mark it reject, raise a nonconformance, and record its number on Form 3.
Common mistakes
Frequent causes of rejected reports are missing characteristics, unballooned notes, wrong drawing revision, results entered without actual values, expired gauges, and a first article made with a prototype process instead of production. Also remember delta FAI: when a design, process, tool, or location changes, a partial FAI may be needed for the affected characteristics. Keep FAI records with the part number history and retain them as the customer requires.
Frequently Asked Questions
Is this an official AS9102 form?
No. It follows the structure and information required by AS9102 across Forms 1, 2 and 3, but it is not a copy of the standard's form. Some customers require their own version, so confirm before submitting.
Can I get the first article inspection report in Excel or Word?
Yes. Fill in the fields, then export the document to Word, PDF, or Excel. Use the Excel export if you want to extend Form 3 with many characteristics and add formulas for tolerance checks.
When is a full FAI required versus a partial one?
A full FAI is required for a new part number and may be required after major changes. A partial (delta) FAI covers only characteristics affected by a change, such as a drawing revision, a process or tooling change, a new location, or a long lapse in production.
How many characteristics should Form 3 include?
All of them: every dimension, tolerance, note, and referenced specification requirement on the drawing and its parts list. The count depends on the part. A simple bracket may have around 20, while a complex assembly may have hundreds.
If your drawings, inspection results, and nonconformance records already sit in an ERP or quality system, we can help assemble FAI packages from them on your own servers. Ask for an expert review.
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