No, a competent CNC shop includes first-article inspection as part of setup cost on first orders; charging separately for FAI is unusual unless you request a full AS9102 package with additional documentation.

What is the difference between FAI and a regular inspection report?

FAI is exhaustive, covering every drawing characteristic on the first part; a regular inspection report is typically a sample check of critical dimensions on parts from the batch.

My supplier says small batches do not need FAI. Is that correct?

It depends on risk: a 5-piece order of simple brackets may not need a formal AS9102 form, but you should still ask for first-part measured values before the rest of the batch is machined.

Can I skip FAI if I trust my supplier?

Even with a trusted supplier, FAI on a new part is cheap insurance against programming errors, misread drawings, or wrong material — mistakes that trusted shops can still make.

First Article Inspection (FAI): What a Real Report Covers and Why It Matters

What FAI Actually Is

First Article Inspection (FAI) is a complete dimensional and characteristic verification of the first part produced from a new setup or drawing revision. A legitimate shop provides FAI at no additional charge on first orders; if a supplier ships your first batch without one, you are essentially acting as their test inspector.

What a Complete FAI Report Covers

Category	What Is Checked	Why It Matters
Dimensions	All drawing dimensions with tolerances	Catches programming or setup errors before the batch runs
Material	Alloy grade, temper, material certificate	Prevents material substitution
Surface finish	Ra values on specified surfaces	Confirms functional surfaces meet spec
Threads	Thread gauging (GO/NO-GO) on all tapped holes	Avoids assembly failures
Special processes	Anodizing thickness, plating adhesion, heat treat hardness	Verifies secondary operations

AS9102 and When FAI Applies

AS9102 is the aerospace FAI format consisting of three forms: part number accountability, product accountability (material and processes), and characteristic accountability (ballooned drawing with measured results). You do not need to work in aerospace to benefit from this structure. FAI applies to the first production run of a new part, or after a drawing revision, material change, tooling change, or supplier change. Repeat orders of an unchanged part usually do not require a full FAI, though periodic first-piece checks at setup are standard.

Actions for Buyers

Request FAI on every first order, regardless of part size or quantity
Confirm the FAI report references the exact drawing revision you approved
For small batches (under 20 pieces), require at least in-process inspection records even if a full AS9102 form is overkill
Compare FAI measured values to your drawing before releasing the batch for shipment

FAI vs. In-Process Inspection

FAI is a one-time event on the first article; in-process inspection is ongoing sampling during production. Both have value: FAI confirms the setup is correct before volume machining begins, while in-process checks catch tool wear and drift as the batch runs. TruPart Precision, an ISO 9001 shop in Dongguan, includes FAI reports on first orders as a standard step. An FAI report is one of the fastest trust signals a CNC supplier can provide, because it shows willingness to be measured against the drawing.

Frequently Asked Questions

Does FAI cost extra?
No, a competent CNC shop includes first-article inspection as part of setup cost on first orders; charging separately for FAI is unusual unless you request a full AS9102 package with additional documentation.
What is the difference between FAI and a regular inspection report?
FAI is exhaustive, covering every drawing characteristic on the first part; a regular inspection report is typically a sample check of critical dimensions on parts from the batch.
My supplier says small batches do not need FAI. Is that correct?
It depends on risk: a 5-piece order of simple brackets may not need a formal AS9102 form, but you should still ask for first-part measured values before the rest of the batch is machined.
Can I skip FAI if I trust my supplier?
Even with a trusted supplier, FAI on a new part is cheap insurance against programming errors, misread drawings, or wrong material — mistakes that trusted shops can still make.