AS9102 FAI vs PFAI

AS9102 First Article Inspection (FAI) vs Production First Article Inspection (PFAI). When each is required and what triggers a re-FAI for CNC parts.

AS9102 FAI vs PFAI explained. AS9102 first article inspection is required for new parts and major changes. PFAI applies to production runs. Re-FAI triggers include drawing revisions, process changes, supplier changes, and 2-year lapses. Hanover, PA aerospace CNC shop.

About AS9102 FAI vs PFAI

AS9102 FAI vs PFAI at Olympus Machining LLC is delivered from our ITAR-registered precision CNC machine shop in Hanover, Pennsylvania (York County). This page (https://www.olympusmachining.com/as9102-fai-vs-pfai) documents the scope, controls, and engineering practices we apply for OEM, aerospace, defense, and medical buyers requesting as9102 fai vs pfai.

Olympus Machining is CAGE 9V9P0, CMMC Level 1 self-attested per FAR 52.204-21, and NAICS 332710. CMM dimensional inspection is performed in-house on Haas HMM 430 and Chien Wei CWB-450-CNC. AS9102 Rev C First Article Inspection packages, material certifications with heat/lot traceability, and Certificates of Conformance are produced on request as part of as9102 fai vs pfai.

To request a quote, supplier qualification documentation, or a controlled copy of our capability statement related to as9102 fai vs pfai, contact info@olympusmachining.com or call (717) 634-5094. Olympus Machining LLC, 639 Frederick Street Suite 1, Hanover, PA 17331.

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    Back to AS9102 FAI Guide

    Full FAI vs Partial FAI (PFAI): When You Need Each

    AS9102 distinguishes between a Full First Article Inspection and a Partial First Article Inspection (PFAI). Choosing the correct scope avoids over-documenting a minor change and — more importantly — avoids under-documenting a significant one. Olympus Machining LLC, an ITAR-registered, CAGE 9V9P0 precision CNC machine shop in Hanover, Pennsylvania, produces both full and partial FAI packages depending on what triggered the requirement.

    When a Full FAI Is Required

    Per AS9102 Rev C, a full FAI covers every characteristic on the drawing — every dimension, GD&T callout, note, surface finish, and material requirement. Full FAI is required at first production, after a two-year lapse in production, after a change in the manufacturing facility, after a major design change, or whenever the customer specifies it on the purchase order.

    • • First-time production of a new part number at a new supplier
    • • Resumption of production after a two-year (or longer) lapse
    • • Transfer of production from one facility to another
    • • Major drawing revision affecting form, fit, or function across multiple characteristics
    • • Customer-mandated full FAI on the purchase order

    When a Partial FAI (PFAI) Is Appropriate

    A PFAI documents only the characteristics affected by a change. Form 1 must indicate that the FAI is partial and reference the original baseline FAI. Form 3 is limited to the impacted characteristics — but the affected scope must be clearly defined and traceable to the change.

    • • A drawing revision that changes only one or a few dimensions or notes
    • • A change in raw material specification that does not affect part geometry
    • • A change to a special process (e.g., new heat-treat vendor)
    • • A tooling change affecting only specific features
    • • A change in the inspection method for specific characteristics

    How Olympus Decides Between Full and Partial

    On every order with a previous FAI on record, our quality lead reviews the change package — drawing rev letter, ECO note, material substitution, special process change — and makes the full vs partial determination based on AS9102 Rev C section 5.4. When the determination is ambiguous (a change that touches multiple characteristics or a process change that may affect adjacent features), we default to a full FAI rather than risk an inadequate PFAI.

    For prime contractors with their own FAI procedures, we follow the prime's flowdown — many primes require full FAI on every revision regardless of scope. That requirement is captured at the purchase order and quoted accordingly.

    Documentation Differences

    Both full and partial FAIs use Form 1, Form 2, and Form 3. The differences are scope and reference:

    • • Form 1: PFAI must check the "Partial" box and list the baseline FAI report number being delta'd.
    • • Form 2: Only the materials or processes affected by the change need to be re-documented; unchanged items can reference the baseline.
    • • Form 3: Only the affected characteristics are listed. The balloon drawing for the PFAI should highlight the changed balloons.

    Related reading: AS9102 FAI complete guide · Balloon drawings for Form 3 · CMM inspection services · Quality assurance overview · Precision CNC machining