First Article Inspection Checklist [FREE PDF]

First Article Inspection (FAI) is a formal verification process confirming that a production process can produce parts that meet all engineering design and specification requirements. AS9100 Rev D clause 8.1.3 mandates FAI for new or revised part configurations, and IATF 16949 clause 8.3.4.2 requires documented evidence of design validation including dimensional and functional verification. A thorough FAI reduces downstream nonconformances, protects regulatory compliance, and provides objective

  • Industry: Aerospace QA
  • Frequency: Per Event
  • Estimated Time: 60-90 minutes
  • Role: QA Engineer
  • Total Items: 36
  • Compliance: AS9100 Rev D Clause 8.1.3 – First Article Inspection, ISO 9001:2015 Clause 8.5.1 – Control of Production and Service Provision, IATF 16949:2016 Clause 8.3.4.2 – Design and Development Validation, SAE AS9102B – Aerospace First Article Inspection Requirement, ASTM E2905 – Standard Practice for Examination and Evaluation of Documents

Documentation & Drawing Review

Verify all design documentation, drawings, and specifications are current and accessible before inspection begins.

  • Is the engineering drawing at the correct revision level matching the purchase order or contract requirements?
  • Has a complete Bill of Materials (BOM) been reviewed and confirmed against the design record?
  • Are all applicable material and process specifications listed on the drawing available and current?
  • Has the First Article Inspection Report (FAIR) form been initiated with all header information completed?
  • Are all customer-specific requirements and special notes on the drawing identified and documented?

Material & Raw Stock Certification

Confirm material traceability, certifications, and compliance with specified material standards.

  • Is a material certification (mill cert or CoC) available for all raw materials used in the part?
  • Does the material certification confirm the correct alloy, temper, or grade as specified on the drawing?
  • Has material heat or lot traceability been recorded on the FAI documentation package?
  • Are any restricted or hazardous substances (e.g., REACH, RoHS) verified and documented if applicable?
  • Is material test evidence (hardness, tensile, or chemical analysis) included in the FAI package where required?

Dimensional & Geometric Inspection

Perform and record all dimensional measurements against drawing tolerances using calibrated equipment.

  • Have all drawing dimensions been ballooned and assigned a characteristic number on the inspection report?
  • Is all measurement equipment used for dimensional inspection calibrated with current calibration labels?
  • Do all measured dimensions fall within the specified tolerances noted on the engineering drawing?
  • Have all Geometric Dimensioning and Tolerancing (GD&T) callouts (flatness, perpendicularity, true position, etc.) been verified?
  • Are actual measured values (not just pass/fail) recorded for every characteristic on the FAIR Form 3?
  • Has a photograph or CMM print been attached to document critical feature measurements?

Surface Finish & Visual Inspection

Assess surface finish requirements, cosmetic acceptance criteria, and absence of visible defects.

  • Does the surface finish meet the Ra or RMS value specified on the drawing, verified with a profilometer or comparator?
  • Is the part free from visible defects such as cracks, burrs, scratches, porosity, or incomplete machining?
  • Have all edges been deburred and broken per drawing or workmanship standard requirements?
  • Is visual inspection being performed under adequate lighting conditions per acceptance criteria?
  • Has a representative photograph of the completed part's surface and general appearance been captured?

Special Processes & Coatings Verification

Verify all special processes (heat treatment, plating, NDT, welding) were performed per specification and are properly certified.

  • Are special process certifications (heat treat, plating, anodize, weld, NDT) available for all processes applied to the part?
  • Are all special process suppliers listed on an Approved Supplier List (ASL) or Approved Processor List (APL)?
  • Does the coating thickness measurement meet the minimum and maximum values specified on the drawing?
  • Has non-destructive testing (NDT) been completed and results documented where drawing-required?
  • Are weld inspection records (visual, PT, RT, or UT) included in the FAI package where welding is performed?

Functional, Fit & Form Verification

Confirm the first article assembles correctly, meets functional requirements, and interfaces properly with mating parts.

  • Has the part been trial-assembled or verified with mating components or a functional gauge to confirm fit?
  • Have all functional tests or performance checks specified in the design record been completed and passed?
  • Is the part correctly identified with required markings (part number, revision, heat/lot, date code) per drawing notes?
  • Has the part been inspected for correct weight within the drawing tolerance if a weight requirement is specified?
  • Recorded weight of the first article sample (if required)?

FAI Disposition & Approval

Document the overall FAI outcome, any open nonconformances, and obtain required approval signatures for production release.

  • Have all nonconforming characteristics been documented on a formal nonconformance report (NCR) or corrective action request?
  • Has the completed FAI package been reviewed and approved by the responsible QA Engineer or Manager?
  • What is the overall FAI disposition for this part?
  • Has the approved FAI package been filed in the quality management system with controlled document retention?
  • Additional observations, open action items, or notes for the FAI package?

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Why Use This First Article Inspection Checklist [FREE PDF]?

This first article inspection checklist [free pdf] helps aerospace qa teams maintain compliance and operational excellence. Designed for qa engineer professionals, this checklist covers 36 critical inspection points across 7 sections. Recommended frequency: per event.

Ensures compliance with AS9100 Rev D Clause 8.1.3 – First Article Inspection, ISO 9001:2015 Clause 8.5.1 – Control of Production and Service Provision, IATF 16949:2016 Clause 8.3.4.2 – Design and Development Validation, SAE AS9102B – Aerospace First Article Inspection Requirement, ASTM E2905 – Standard Practice for Examination and Evaluation of Documents. Regulatory-aligned for audit readiness and inspection documentation.

Frequently Asked Questions

What does the First Article Inspection Checklist [FREE PDF] cover?

This checklist covers 36 inspection items across 7 sections: Documentation & Drawing Review, Material & Raw Stock Certification, Dimensional & Geometric Inspection, Surface Finish & Visual Inspection, Special Processes & Coatings Verification, Functional, Fit & Form Verification, FAI Disposition & Approval. It is designed for aerospace qa operations and compliance.

How often should this checklist be completed?

This checklist should be completed per event. Each completion takes approximately 60-90 minutes.

Who should use this First Article Inspection Checklist [FREE PDF]?

This checklist is designed for QA Engineer professionals in the aerospace qa industry. It can be used for self-assessments, team audits, and regulatory compliance documentation.

Can I download this checklist as a PDF?

Yes, this checklist is available as a free PDF download. You can also use it digitally in the POPProbe mobile app for real-time data capture, photo documentation, and automatic reporting.

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