AS9102 is the aerospace standard that defines how to perform and document First Article Inspections. It harmonizes expectations across the aviation, space, and defense supply chain so buyers get consistent, complete verification of design, materials, special processes, and dimensions. The latest revision is AS9102 Rev C (June 28, 2023). sae.orgIAQG
When an FAI is required
Typical triggers include:
- New part / first production run (full FAI).
- Design change affecting form, fit, or function (partial or full).
- Process, tooling, material, supplier, or location change that could affect form/fit/function (partial or full).
- Lapse in production > 2 years (full or as specified by customer). Collins AerospaceLockheed MartinNet-Inspect
What’s in an AS9102 FAI package
- Form 1 – Part Number Accountability (part numbers, revisions, and build info).
- Form 2 – Product Accountability (raw materials, specs, special processes, functional tests—e.g., autoclave cure or NDI callouts).
- Form 3 – Characteristic Accountability (every drawing/model characteristic with actual results), supported by a ballooned drawing/model numbered to match Form 3. InspectionXpert+1Industrial Inspection & Analysis (IIA)guthcad.com
Composites-specific FAI expectations (what buyers should ask for)
For composite structures, a robust FAI typically includes:
- Material traceability: prepreg batch/roll IDs, core (Nomex/Al) lots, adhesive films, bagging materials, freezer logs. (Form 2 materials/special processes.) Industrial Inspection & Analysis (IIA)
- Process records: layup travelers/ply books, debulk steps, cure cycle charts (autoclave/OOA/RTM), tool IDs, and post-cure data. (Form 2 special processes.) Industrial Inspection & Analysis (IIA)
- Dimensional verification: CMM/laser results, trim/drill programs referenced on Form 3; all ballooned features accounted for. InspectionXpert
- NDI evidence: ultrasonic C-scan or agreed visual acceptance, plus disposition of indications (when required by drawing/spec). Industrial Inspection & Analysis (IIA)
- Hardware & inserts: torque values, bondline controls, potting details, and adhesive cure verification (where applicable). Industrial Inspection & Analysis (IIA)
Full vs. Partial (Delta) FAI
- Full FAI: new part or when broad changes invalidate prior results.
- Partial / Delta FAI: only the changed characteristics or processes are re-inspected and documented, with cross-references to the baseline FAI. Rev C emphasizes clear planning and re-accomplishment criteria. Net-Inspect+1
Our FAI process for composite parts (CUG)
- Plan & bubble – Identify key and critical characteristics; balloon the drawing/model and map to inspection plan. InspectionXpert
- Material & process accountability – Capture raw material certs and special process parameters (cure charts, tool IDs, NDI plans). Industrial Inspection & Analysis (IIA)
- Build & record – Execute travelers/ply books; collect cure/NDI data.
- Measure & verify – CMM/hand tools/functional tests per drawing and specs; complete Form 3 with actuals. InspectionXpert
- Package & submit – Deliver FAIR (Forms 1–3), ballooned drawing/model, certs, and objective evidence aligned to AS9102 Rev C. sae.org
Common FAI pitfalls in composites (and how we prevent them)
- Missing special-process evidence (e.g., autoclave charts). Prevention: tie each operation to a tool ID and cure record referenced on Form 2. Industrial Inspection & Analysis (IIA)
- Unballooned notes/dimensions left off Form 3. Prevention: 100% characteristic accountability with balloon-to-Form-3 parity. InspectionXpert
- Unclear re-accomplishment logic after changes. Prevention: Rev-controlled FAI plan defining full vs. delta triggers. Net-Inspect
- Production restarts after long gaps without FAI. Prevention: policy to perform FAI at >2 years lapse or per contract. Lockheed Martin
FAQs
Is AS9102 mandatory for composite parts?
If your customer or contract calls out AS9102, then yes—the FAI must follow that standard and use its documentation framework. Many aerospace/defense buyers require it to standardize expectations. IAQG
What documents do I receive?
A complete FAIR with Forms 1–3, the ballooned drawing/model, material certs, special-process records (e.g., cure charts), NDI evidence, and dimensional reports. InspectionXpertIndustrial Inspection & Analysis (IIA)
When do I need a new FAI?
At new part introduction; after design, process, tooling, material, supplier, or location changes that could affect form/fit/function; and after >2 years without production (or per customer spec). Collins AerospaceLockheed Martin
What’s the difference between full and partial FAI?
Full re-verifies all characteristics; partial/delta re-verifies only the changed ones and references the baseline FAIR—an approach reinforced in Rev C. Net-Inspect+1
Why CUG
- Composite-savvy FAIRs: We understand ply-level traceability, cure discipline, bonded assembly controls, and NDI evidence.
- Audit-ready: Our FAIRs align to AS9102 Rev C and common buyer supplements. sae.org
- Speed & completeness: We plan delta vs. full up front to keep your schedule intact without sacrificing compliance. Net-Inspect
Need an AS9102 FAIR for your composite part?
Send drawings/models and spec stack. We’ll return a scope, schedule, and sample FAIR outline tailored to your program.