Sheet Metal First Article Inspection Report Template
A first article inspection (FAI) proves that the first parts off a new setup meet the drawing before the full lot is run. This template gives fabricators a clean report with ballooned characteristics, measured values and sign-off.
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Sheet Metal First Article Inspection Report Template
First Article Inspection Report
Supplier: Northline Metalworks Customer: Harlan Enclosures Inc. Part: HE-2204-B rev C PO: PO-77412 Reason: New part
Material
5052-H32, 2.0 mm, mill cert L-55318
Measuring equipment
Digital caliper ID C-114, bevel protractor ID P-021, height gauge ID H-007. Calibration current.
Characteristics
| Balloon | Feature | Requirement | Tolerance | Measured | Pass / Fail |
|---|---|---|---|---|---|
| 1 | Overall length | ||||
| 2 | Overall width | ||||
| 3 | Hole diameter | ||||
| 4 | Hole position to datum A | ||||
| 5 | Flange height | ||||
| 6 | Bend angle | 90 deg | +/- 1 deg | ||
| 7 | Flatness | ||||
| 8 | Hardware seated (PEM) | Flush | |||
| 9 | Finish and color |
Result
Overall result: Accepted Inspector: R. Banda Date: 2026-10-20
Approvals
This is a general structure for first article reports on fabricated parts, not a copy of any customer or industry form. If your customer requires AS9102 or a PPAP package, use that required format.
Connect inspection data to your ERP
Optional: a short chat on storing FAI and inspection results against items and lots.
Optional. The tool and every export work without this. No spam.
How to use the report
Balloon every dimension, note and tolerance on the drawing and number them. List each balloon in the table with the requirement and tolerance, then measure the first piece and write the actual value. Mark pass or fail per row. Set the overall result and sign. Keep the marked-up drawing with the report so a reviewer can trace each number. Run the FAI before releasing the lot to the next operation.
When an FAI is needed
Typical triggers are a new part number, a revision change, a major tooling or program change, a move to a new machine or a long gap in production. Many customer quality agreements spell out their own triggers, so check the terms. Even when not required, an FAI on a new bent and welded part catches program errors early, when only one piece is affected.
- New part or new revision
- New tooling, die or laser program
- Process or location change
- Extended production break
Measuring sheet metal parts
Flat features such as hole size and position can be measured with calipers, pin gauges or a CMM. Bend angles are usually checked with a protractor or an angle gauge, and flange lengths with a height gauge or a profile fixture. Account for springback on formed parts and measure after the part has settled. Record equipment IDs so calibration can be verified later.
Common mistakes
Skipping notes and finish requirements on the drawing is common; they count as characteristics. Another miss is measuring a part that was hand tuned and cannot be repeated by production. Run the FAI part on the actual production setup. Also avoid rounding measured values to the tolerance limit; record what the gauge shows.
Frequently Asked Questions
Is this the same as AS9102?
No. It is a general first article report for fabricated parts. AS9102 has specific forms and rules for aerospace. If your customer requires AS9102, use its required forms instead of this template.
How many parts should I measure?
A first article is typically one representative piece, though some customers require several. Follow the quality agreement. For critical features you may also want a short capability check on additional parts.
Do I need to balloon the drawing?
Yes, ballooning gives each requirement a number that links drawing and report. It also makes sure no dimension or note is skipped. Ballooning can be done on a PDF markup or on a printed copy.
Can I add more characteristics?
Yes. The table has nine starter rows. Export to Word or Excel and add rows for every balloon on your drawing.
If you want FAI data to feed supplier scorecards or ERP quality records, we can discuss how to capture it without retyping.
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