First Article Inspection Report Template (Excel, AS9102 Forms 1, 2, 3)
This first article inspection report template follows the AS9102 FAI structure: Form 1 for part accountability, Form 2 for materials, special processes and tests, and Form 3 for every ballooned characteristic. Fill it in, then export to Excel, PDF or Word.
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First Article Inspection Report Template (AS9102, Excel)
First Article Inspection Report
FAI report no: FAI-2026-017 Type: Full FAI Reason: New part Inspection date: 2026-10-18
Form 1: Part Number Accountability
| Field | Entry |
|---|---|
| Part number | PN-48213 |
| Part name | Bracket, Mounting |
| Drawing revision | C |
| Serial or lot | Lot 4471, S/N 001 |
| Manufacturer and CAGE | Acme Precision Ltd [CAGE code (if applicable)] |
| Customer PO | PO-77120 |
| Overall FAI result | Accepted |
Form 2: Product Accountability (materials, special processes, functional tests)
Aluminum 6061-T6 bar, AMS-QQ-A-225/8; anodize Type II per MIL-A-8625, approved process source on file.
| Item | Specification | Supplier or process source | Cert no | Result |
|---|---|---|---|---|
| Raw material | ||||
| Special process | ||||
| Functional test |
Form 3: Characteristic Accountability, Verification and Compatibility
| Balloon | Requirement and tolerance | Method and gauge | Actual result | Pass/Fail |
|---|---|---|---|---|
| 1 | ||||
| 2 | ||||
| 3 | ||||
| 4 | ||||
| 5 |
Approvals
This template follows the structure of AS9102 (Forms 1, 2 and 3) in our own wording and is not the official form. Check your customer's flowdown for required fields. Ballooning: number every drawing characteristic once, in sequence, including notes, tolerances, surface finish, material and special-process requirements, and carry each number through to Form 3.
Draft FAI packages from ERP data
Optional: see how part, revision and certificate data could pre-fill FAI reports inside your own environment.
Optional. The tool and every export work without this. No spam.
How to use the FAI report template
Enter the part, revision, FAI type and reason, then complete Form 2 for raw material, special processes and functional tests. Balloon the drawing first: every dimension, tolerance, note, finish and specification gets one unique number, and Form 3 lists one row per balloon. Measure the first article produced on the actual production process and tooling, record actual values rather than 'OK', and mark pass or fail against the tolerance. Export to Excel to extend Form 3 for parts with many characteristics.
- Balloon the latest released drawing revision only.
- One characteristic per row; split multi-feature callouts.
- Record measured values and the gauge or method used.
- Attach certificates and test reports referenced in Form 2.
- Use a partial (delta) FAI only for the changed characteristics and their dependents.
When an FAI is required and what the three forms hold
AS9102 is the aerospace standard for first article inspection, invoked through AS9100 and customer contracts. A full FAI is typically needed for a new part, after a drawing or process change that affects form, fit or function, after a change of manufacturing location or tooling, or after a long lapse in production. Form 1 identifies the part and the FAI. Form 2 proves that materials and special processes come from approved sources and meet the specification. Form 3 shows every design characteristic was verified against requirements. Wording here is paraphrased; use your contract and the current standard for the exact requirements.
Common mistakes and how to avoid them
The most frequent rejections are missing characteristics on Form 3, drawing revision mismatch between the balloon drawing and the part, values entered as pass without actuals, special process certificates not traceable to the part, and no FAI after a process change. Keep the ballooned drawing with the report, use the same balloon numbers across revisions where possible, and file the FAI as a controlled record with a number that links to the production order in your ERP.
Frequently Asked Questions
What is an AS9102 first article inspection report?
It is the documented verification that a first production part meets all drawing and specification requirements, organised in three forms: part number accountability, product accountability, and characteristic accountability. It is required by many aerospace and defense customers.
Is this the official AS9102 form?
No. It follows the structure of the three forms in our own wording so it is free to use and edit. Always confirm the exact fields your customer requires.
How many characteristics do I have to list?
All design characteristics on the drawing and in referenced specifications, each ballooned and verified. Complex parts can have hundreds, so export to Excel and extend Form 3 as needed.
Can I use this as a general FAI format for non-aerospace parts?
Yes. The structure works for any part where you need documented proof that the first piece meets every requirement; drop fields you do not need.
Netray can add a private AI layer on your servers that pulls part, revision, lot and certificate data from your ERP into FAI drafts, with an inspector reviewing every entry.
Related Tools
AS9102 Form 1 Part Number Accountability Template
Generate the Form 1 header page of an AS9102 first article inspection report with part, drawing, FAI type and approval blocks.
Aerospace & DefenseAS9102 Form 2 Product Accountability Template
Fill in AS9102 Form 2 style product accountability records for raw materials, special processes and functional tests, then export a PDF or Word file.
Aerospace & DefenseAS9102 Form 3 Characteristic Accountability Worksheet
Record each ballooned characteristic with nominal, tolerance, actual and automatic pass or fail, then export to Excel.
Aerospace & DefenseFirst Article Inspection (AS9102) Checklist
A 30-point checklist for complete, first-pass-acceptable AS9102 FAIs - planning, Form 1/2/3 completeness, characteristic accountability, and the delta FAI triggers teams miss.
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