First article inspection (FAI)
First article inspection (FAI) is a documented check of the first unit from a new production setup against its drawings, BOM and specifications. It confirms that the process can build the product correctly before the rest of the batch is made. In PCB assembly, FAI verifies component values, polarity, placement and solder quality.
First article inspection explained
First article inspection is a gate between setting up a process and running it. The first board — or the first few — produced after setup is inspected in detail and compared with the design data. Only when the first article passes does production continue.
In PCB assembly, the inspection usually covers several areas. Every placed component is checked against the BOM for part number, value and package. Polarity and orientation are checked for diodes, electrolytic capacitors, ICs and connectors. Positions are compared with the assembly drawing and the pick-and-place file. Solder joints are assessed against the agreed IPC-A-610 class, often with help from AOI and, for hidden joints, X-ray inspection. Passive values may be measured with an LCR meter or a dedicated FAI system that compares readings with the BOM.
For bare boards, a first article may include dimensional checks, hole sizes, plating thickness, impedance test coupons and microsections.
The result is a first article inspection report: a record of each characteristic checked, the requirement, the measured result and a pass or fail. Depending on the industry, the report may follow a customer template, an automotive approval process or the aerospace standard AS9102.
A new FAI is normally required when something significant changes: a new design revision, a new manufacturer or production site, new tooling or programs, a change of component source, or a long gap since the last production run.
When first article inspection matters
FAI matters most at the start of production for a new or changed design. It catches systematic errors — a wrong reel loaded on a feeder, a rotated footprint, an incorrect value in the BOM — on one board instead of a full batch.
It is particularly valuable for high-mix, low-volume work, where setups change often, and for boards with many similar-looking parts. It is usually mandatory in regulated sectors: aerospace and defence programmes commonly require AS9102 FAI, and automotive customers require production part approval.
FAI also protects the customer. A signed first article report gives a reference point: later batches can be compared with it, and disagreements about what was agreed are easier to settle. When FAI is skipped, errors may only appear at functional test or in the field. The trade-off is time and cost, so the scope should match the risk of the product.
FAI vs PPAP vs AS9102 first article inspection
A general FAI checks one unit. PPAP proves that the whole production process is capable and controlled. AS9102 defines a strict, standard format for aerospace first article records. For most commercial PCB assemblies, a general FAI report agreed with the manufacturer is enough; PPAP and AS9102 apply when the customer's sector requires them.
First article inspection in your quote request
In your quote request, state whether you need a first article inspection and in what format, for example a customer template, AS9102 forms or a PPAP submission level. Say whether production should wait for your approval of the first article, how many first articles you need and which inspection methods you expect, such as X-ray for BGAs. Include the BOM, assembly drawing and pick-and-place file at the current revision, because the FAI is checked against them.
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PCB assembly →FAQ about first article inspection
What is a first article inspection?
A first article inspection is a formal check of the first unit produced after a new production setup. Every relevant characteristic is compared with the drawings, BOM and specifications, and the results are recorded in a report. In PCB assembly this covers component values, polarity, placement and solder joints. Production of the full batch normally continues only after the first article passes.
When should a first article inspection be done?
A first article inspection should be done before the first production run of a new design, and again after significant changes. Typical triggers are a new design revision, a change of manufacturer or production site, new tooling or machine programs, a change of component source, and a long break in production. Many contracts and industry standards define these triggers explicitly.
What is the difference between PPAP and first article inspection?
A first article inspection checks that one unit matches the design. PPAP, the automotive Production Part Approval Process defined by AIAG, is broader: it demonstrates that the whole production process can consistently produce conforming parts. A PPAP package can include dimensional results, process flow, control plans, FMEA, capability studies and material records, so a first article inspection is only one part of it.
Does AS9100 require first article inspection?
Yes. AS9100, the aerospace quality management standard, requires organisations to perform production process verification, and first article inspection is the usual way to do it. The method and documentation for that inspection are defined in AS9102, which specifies standard forms for part identification, material and process records, and characteristic accountability. Customers in aerospace and defence normally require AS9102-format reports.
Related terms
- IPC-A-610
IPC-A-610 is the IPC standard that defines visual acceptance criteria for electronic assemblies. It describes what acceptable and defective solder joints, component placement, cleanliness and damage look like on a populated PCB, using photographs and illustrations, across three product classes. It is the most widely used inspection standard in PCB assembly.
- AOI
AOI (Automated Optical Inspection) uses high-resolution cameras to inspect solder joints, component placement, and orientation after assembly. Modern 3D AOI measures joint height and volume volumetrically, catching defects like lifted leads and insufficient solder that 2D systems miss. Limited to visible surfaces — hidden joints under BGAs require X-ray inspection.
- X-ray inspection
X-ray inspection is a non-destructive testing method that penetrates the PCB to reveal hidden solder joints under BGAs, QFNs, and other bottom-terminated packages. It detects voids, head-in-pillow defects, bridging, and missing joints that AOI cannot see. Available in 2D (top-down) and 3D CT (full volumetric) variants.
- BOM
A BOM (Bill of Materials) is the structured list of every component needed to build a PCB, mapping reference designators on the board to specific manufacturer parts. It is one of the three core files — alongside Gerber and pick and place — required to quote and assemble a PCBA.
- PCBA
PCBA (Printed Circuit Board Assembly) is the process of populating a bare PCB with electronic components — resistors, capacitors, ICs, connectors, and other parts — to produce a functional electronic assembly ready for testing or integration into a finished product.
- NRE cost
NRE (Non-Recurring Engineering) cost is the one-time charge for setup work that does not repeat per unit — tooling, stencils, programming, jigs, test fixtures, first-article inspection, and engineering review. NRE is paid once per design revision and is amortised across the production volume, making per-unit cost lower at higher quantities.