--- title: "Full FAI vs Partial FAI (PFAI): When To Use Each | Olympus" description: "Decision guide for full AS9102 FAI vs Partial FAI. Triggers, scope, and documentation differences for aerospace and defense CNC parts. 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CNC Machining](/materials/peek-cnc-machining) [Inconel CNC Machining Guide](/materials/inconel-cnc-machining-guide) ![Olympus Machining LLC logo — precision CNC machining shop in Hanover, Pennsylvania](/assets/olympus-logo-DbWcTX06.webp) HomeAboutServices[Blog](/blog)Contact[Careers](/careers)[(717) 634-5094 ](tel:+17176345094)[Login](/auth)Get Quote [Back to AS9102 FAI Guide](/as9102-first-article-inspection) # 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](/as9102-first-article-inspection) · [Balloon drawings for Form 3](/as9102-balloon-drawings) · [CMM inspection services](/cmm-inspection-services) · [Quality assurance overview](/quality-assurance) · [Precision CNC machining](/precision-cnc-machining) [CNC Milling](/cnc-milling) [CNC Turning](/cnc-turning) [Quality Assurance](/quality-assurance) [Prototype to Production](/prototype-to-production) [Industries Served](/industries-served) [Materials Machined](/materials-machined) [Robotics & Automation Machining](/robotics-automation-machining) [Precision CNC Machining](/precision-cnc-machining) [Careers](/careers) [ITAR CNC Machining for Mid-Atlantic Aerospace OEMs](/itar-cnc-machining-mid-atlantic-aerospace) [CNC Tolerances & GD&T Guide](/resources/cnc-machining-tolerances-gdt-guide) [Reducing CNC Machining Costs](/resources/reducing-cnc-machining-costs) [6061 vs 7075 Aluminum](/materials/6061-vs-7075-aluminum) [Brass vs Bronze Machining](/materials/brass-vs-bronze-machining) [![Olympus Machining LLC logo — CNC machining shop Hanover, PA](/assets/olympus-logo-DbWcTX06.webp)](/) Olympus Machining LLC is a precision CNC machining shop in Hanover, Pennsylvania, providing CNC milling and turning services for OEMs and manufacturers nationwide. 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