--- title: "AS9102 First Article Inspection (FAI) Guide | Olympus" description: "AS9102 FAI guide for aerospace and defense CNC parts. Form 1 / 2 / 3 walkthrough, CMM workflow, ITAR-compliant documentation from Hanover, PA." lang: en json-ld: | [ { "@context": "https://schema.org", "@graph": [ { "@type": "Organization", "@id": "https://www.olympusmachining.com/#organization", "name": "Olympus Machining LLC", "url": "https://www.olympusmachining.com", "logo": "https://storage.googleapis.com/gpt-engineer-file-uploads/SFKHg3gA6NVscESUCStAZeugW5B3/social-images/social-1762640845290-Olympus-Machining-Gear-Logo_Logo-ONLY.png", "description": "Olympus Machining LLC is a precision CNC machining shop located in Hanover, Pennsylvania, providing CNC milling and CNC turning services for OEMs and manufacturers nationwide.", "telephone": "+17176345094", "email": "info@olympusmachining.com", "address": { "@type": "PostalAddress", "streetAddress": "639 Frederick St, Suite 1", "addressLocality": "Hanover", "addressRegion": "PA", "postalCode": "17331", "addressCountry": "US" }, "sameAs": [ "https://www.google.com/maps/place/Olympus+Machining+LLC" ], "hasCredential": [ { "@type": "EducationalOccupationalCredential", "name": "ITAR Registration — DDTC", "credentialCategory": "Government Registration", "recognizedBy": { "@type": "Organization", "name": "U.S. Directorate of Defense Trade Controls (DDTC)" } }, { "@type": "EducationalOccupationalCredential", "name": "CMMC Level 1 Compliance", "credentialCategory": "Compliance Certification" } ] }, { "@type": [ "LocalBusiness", "ManufacturingBusiness" ], "@id": "https://www.olympusmachining.com/#localbusiness", "name": "Olympus Machining LLC", "image": "https://storage.googleapis.com/gpt-engineer-file-uploads/SFKHg3gA6NVscESUCStAZeugW5B3/social-images/social-1762640845290-Olympus-Machining-Gear-Logo_Logo-ONLY.png", "description": "Olympus Machining LLC is a precision CNC machining shop located in Hanover, Pennsylvania. We provide CNC milling, CNC turning, and prototype-to-production machining services for OEMs and manufacturers nationwide.", "address": { "@type": "PostalAddress", "streetAddress": "639 Frederick St, Suite 1", "addressLocality": "Hanover", "addressRegion": "PA", "postalCode": "17331", "addressCountry": "US" }, "telephone": "+17176345094", "email": "info@olympusmachining.com", "url": "https://www.olympusmachining.com", "priceRange": "$$", "areaServed": "United States", "aggregateRating": { "@type": "AggregateRating", "ratingValue": "5.0", "reviewCount": "15", "bestRating": "5", "worstRating": "1" }, "review": [ { "@type": "Review", "author": { "@type": "Person", "name": "Michael R." }, "reviewRating": { "@type": "Rating", "ratingValue": "5", "bestRating": "5" }, "reviewBody": "Olympus Machining delivered precise aluminum components for our robotics end-of-arm tooling on time and at a fair price." }, { "@type": "Review", "author": { "@type": "Person", "name": "Sarah T." }, "reviewRating": { "@type": "Rating", "ratingValue": "5", "bestRating": "5" }, "reviewBody": "We needed ITAR-compliant machining for defense hardware and Olympus Machining handled it professionally." }, { "@type": "Review", "author": { "@type": "Person", "name": "Dave K." }, "reviewRating": { "@type": "Rating", "ratingValue": "5", "bestRating": "5" }, "reviewBody": "Great CNC shop for prototype work. They provided DFM feedback that saved us time and cost." } ], "hasOfferCatalog": { "@type": "OfferCatalog", "name": "Olympus Machining CNC Services", "itemListElement": [ { "@type": "Offer", "itemOffered": { "@type": "Service", "@id": "https://www.olympusmachining.com/cnc-milling#service", "name": "CNC Milling Services", "url": "https://www.olympusmachining.com/cnc-milling", "provider": { "@id": "https://www.olympusmachining.com/#organization" } } }, { "@type": "Offer", "itemOffered": { "@type": "Service", "@id": "https://www.olympusmachining.com/cnc-turning#service", "name": "CNC Turning Services", "url": "https://www.olympusmachining.com/cnc-turning", "provider": { "@id": "https://www.olympusmachining.com/#organization" } } }, { "@type": "Offer", "itemOffered": { "@type": "Service", "@id": "https://www.olympusmachining.com/prototype-to-production#service", "name": "Prototype to Production Machining", "url": "https://www.olympusmachining.com/prototype-to-production", "provider": { "@id": "https://www.olympusmachining.com/#organization" } } }, { "@type": "Offer", "itemOffered": { "@type": "Service", "name": "ITAR Registered CNC Machining", "provider": { "@id": "https://www.olympusmachining.com/#organization" } } } ] } } ] }, { "@context": "https://schema.org", "@graph": [ { "@type": [ "LocalBusiness", "ManufacturingBusiness" ], "@id": "https://www.olympusmachining.com/#organization", "name": "Olympus Machining LLC", "alternateName": "Olympus Machining", "url": "https://www.olympusmachining.com", "logo": { "@type": "ImageObject", "url": "https://www.olympusmachining.com/images/olympus-logo.png", "width": 300, "height": 100 }, "image": "https://www.olympusmachining.com/images/olympus-machining-headquarters-hanover-pa.jpg", "description": "Olympus Machining LLC is a U.S.-based precision CNC machining shop in Hanover, Pennsylvania, providing CNC milling, CNC turning, and prototype-to-production machining services for OEMs and manufacturers nationwide.", "telephone": "+1-717-634-5094", "email": "info@olympusmachining.com", "address": { "@type": "PostalAddress", "streetAddress": "639 Frederick St, Suite 1", "addressLocality": "Hanover", "addressRegion": "PA", "postalCode": "17331", "addressCountry": "US" }, "geo": { "@type": "GeoCoordinates", "latitude": 39.8007, "longitude": -76.9836 }, "areaServed": { "@type": "Country", "name": "United States" }, "priceRange": "$$", "sameAs": [ "https://www.google.com/search?sca_esv=2f4ed381b998a4d8&sxsrf=AE3TifODgJgBq4b1RAZEZnaHSJwX6ZOvSg:1767447357236&kgmid=/g/11kr8nzb2c&q=Olympus+Machining+LLC&shndl=30&shem=ptotplc,shrtsdl&source=sh/x/loc/uni/m1/1&kgs=100779a69d016c62&utm_source=ptotplc,shrtsdl,sh/x/loc/uni/m1/1", "https://www.instagram.com/olympusmachining/" ], "knowsAbout": [ "CNC Milling", "CNC Turning", "Precision CNC Machining", "Prototype Machining", "Short-Run Production", "Robotics Machining", "Quality Assurance", "First Article Inspection", "ITAR Compliance" ], "hasOfferCatalog": { "@type": "OfferCatalog", "name": "CNC Machining Services", "itemListElement": [ { "@type": "OfferCatalog", "name": "CNC Milling Services", "url": "https://www.olympusmachining.com/cnc-milling" }, { "@type": "OfferCatalog", "name": "CNC Turning Services", "url": "https://www.olympusmachining.com/cnc-turning" }, { "@type": "OfferCatalog", "name": "Precision CNC Machining", "url": "https://www.olympusmachining.com/precision-cnc-machining" }, { "@type": "OfferCatalog", "name": "Prototype to Production", "url": "https://www.olympusmachining.com/prototype-to-production" }, { "@type": "OfferCatalog", "name": "Robotics & Automation Machining", "url": "https://www.olympusmachining.com/robotics-automation-machining" } ] } }, { "@type": "WebSite", "@id": "https://www.olympusmachining.com/#website", "name": "Olympus Machining", "url": "https://www.olympusmachining.com", "publisher": { "@id": "https://www.olympusmachining.com/#organization" }, "potentialAction": { "@type": "SearchAction", "target": "https://www.olympusmachining.com/?s={search_term_string}", "query-input": "required name=search_term_string" } }, { "@type": "WebPage", "@id": "https://www.olympusmachining.com/as9102-first-article-inspection#webpage", "name": "AS9102 First Article Inspection (FAI) Guide for CNC Machined Parts | Olympus Machining", "description": "Complete AS9102 FAI guide for aerospace and defense CNC parts. Form 1 / Form 2 / Form 3 walkthrough, CMM inspection workflow, ITAR-compliant documentation. Hanover PA.", "url": "https://www.olympusmachining.com/as9102-first-article-inspection", "isPartOf": { "@id": "https://www.olympusmachining.com/#website" }, "about": { "@id": "https://www.olympusmachining.com/#organization" }, "inLanguage": "en-US" }, { "@type": "BreadcrumbList", "itemListElement": [ { "@type": "ListItem", "position": 1, "name": "Home", "item": "https://www.olympusmachining.com" }, { "@type": "ListItem", "position": 2, "name": "AS9102 First Article Inspection", "item": "https://www.olympusmachining.com/as9102-first-article-inspection" } ] }, { "@type": "Service", "@id": "https://www.olympusmachining.com/as9102-first-article-inspection#service", "name": "AS9102 First Article Inspection", "description": "AS9102 Rev C First Article Inspection (FAI) for CNC machined aerospace and defense components. Form 1, Form 2, and Form 3 documentation produced from CMM data on Haas HMM 430 and Chien Wei CWB-450-CNC.", "url": "https://www.olympusmachining.com/as9102-first-article-inspection", "provider": { "@id": "https://www.olympusmachining.com/#organization" }, "areaServed": { "@type": "Country", "name": "United States" }, "serviceType": [ "AS9102 FAI", "First Article Inspection", "CMM Inspection", "Aerospace Quality Documentation", "ITAR Compliant Inspection" ] }, { "@type": "FAQPage", "@id": "https://www.olympusmachining.com/as9102-first-article-inspection#faq", "mainEntity": [ { "@type": "Question", "name": "When is an AS9102 First Article Inspection required?", "acceptedAnswer": { "@type": "Answer", "text": "FAI is required when (1) a part is produced for the first time at a facility, (2) any design, tooling, process, supplier, or location change is made that could affect the part, (3) two or more years have lapsed since the last production run, or (4) the customer purchase order specifies it. Common triggers include a drawing revision change, a material substitution, a CNC program change that affects a controlled characteristic, or an outside-process supplier change (e.g., switching anodize vendors)." } }, { "@type": "Question", "name": "What is the difference between a full FAI and a Partial FAI (PFAI)?", "acceptedAnswer": { "@type": "Answer", "text": "A full FAI documents every characteristic on the drawing. A Partial FAI (PFAI) documents only the characteristics affected by a specific change — for example, just the features impacted by a revision or by a process change. The Form 1 must indicate it is a PFAI, the Form 1 'Reason for Partial FAI' field must be populated, and Form 3 must reference the prior full FAI for the unaffected characteristics. See our dedicated guide at /as9102-fai-vs-pfai." } }, { "@type": "Question", "name": "What revision of AS9102 does Olympus produce packages to?", "acceptedAnswer": { "@type": "Answer", "text": "Olympus Machining produces FAI packages to AS9102 Rev C (released August 2023) by default. Rev C clarifies the treatment of model-based definition (MBD), expands PFAI guidance, formalizes the handling of additive-manufactured characteristics, and tightens special-process traceability. If a customer purchase order specifies Rev B or an earlier revision, we produce to the specified revision instead." } }, { "@type": "Question", "name": "Who issues the AS9102 standard?", "acceptedAnswer": { "@type": "Answer", "text": "AS9102 is published by SAE International (and harmonized internationally as EN 9102 in Europe and JISQ 9102 in Japan) under the IAQG 9100-series aerospace quality framework. Blank forms can be downloaded directly from SAE at sae.org. Olympus Machining produces packages on the official SAE forms or the customer-specified equivalent." } }, { "@type": "Question", "name": "What information does Form 1 capture?", "acceptedAnswer": { "@type": "Answer", "text": "Form 1 establishes part-number accountability: part number, part name, drawing number and revision, serial or lot number, manufacturing process record (router/traveler/work order number), full-FAI vs PFAI indicator, and — for assemblies — every sub-component part number with an indicator showing whether each sub-component has its own FAI. Form 1 also records the FAI report number and reporting organization." } }, { "@type": "Question", "name": "What information does Form 2 capture?", "acceptedAnswer": { "@type": "Answer", "text": "Form 2 documents product accountability for materials and special processes. Each row captures a material or special-process specification (e.g., AMS-QQ-A-250/11 for 6061-T6 plate, AMS 2700 for stainless passivation), the actual certification number, the supplier or processor name, supplier code, and date of certification. Outside-process certifications (heat treat, plating, anodize, NDT, welding) are bound into the package alongside Olympus's internal documentation." } }, { "@type": "Question", "name": "What information does Form 3 capture?", "acceptedAnswer": { "@type": "Answer", "text": "Form 3 is the dimensional report. Every drawing characteristic — dimension, tolerance, GD&T callout, surface finish, material requirement, and note — is assigned a balloon number on a balloon-annotated drawing. Form 3 then lists, for each balloon: the requirement (nominal + tolerance), the actual measured value, the inspection method (CMM, micrometer, gage pin, vision system, visual), and the accept/reject result. Designated Key Characteristics are flagged separately." } }, { "@type": "Question", "name": "Do drawing notes need to be ballooned on Form 3?", "acceptedAnswer": { "@type": "Answer", "text": "Yes. AS9102 Rev C requires every drawing requirement — including notes for heat treat, surface treatment, marking, finish, packaging callouts, and material specifications — to be balloon-numbered and recorded on Form 3. Treating notes as 'inspected by certification' rather than ballooning them is one of the most common audit findings. Olympus balloons notes as discrete characteristics and references the supporting certification or measurement evidence." } }, { "@type": "Question", "name": "What inspection equipment does Olympus use for FAI?", "acceptedAnswer": { "@type": "Answer", "text": "Dimensional inspection is performed on a Haas HMM 430 cantilever CMM and a Chien Wei CWB-450-CNC. Supplemental inspection uses calibrated micrometers, height gages, bore gages, gage pins, thread ring/plug gages, an optical comparator, and a surface-finish profilometer. All gages are tracked in our calibration system with documented traceability to NIST." } }, { "@type": "Question", "name": "How long does FAI take to complete?", "acceptedAnswer": { "@type": "Answer", "text": "For typical CNC-machined parts, FAI documentation runs 1–3 business days after the first article comes off the setup — driven primarily by characteristic count, CMM programming time, and the volume of special-process certifications that need to be bound in. For complex assemblies with deep sub-component FAIs, the timeline extends accordingly. The FAI line item is quoted separately on the purchase order so there are no surprises." } }, { "@type": "Question", "name": "How does Olympus handle out-of-tolerance characteristics found during FAI?", "acceptedAnswer": { "@type": "Answer", "text": "Any out-of-tolerance condition triggers an internal Material Review Board (MRB) hold. The part is not shipped until the disposition is documented: rework to bring back into tolerance, use-as-is with documented customer concurrence (deviation/waiver), or scrap. The disposition record is bound into the FAI package and referenced from Form 3 so the customer's incoming quality team sees the full audit trail." } }, { "@type": "Question", "name": "Does the customer need to provide blank AS9102 templates?", "acceptedAnswer": { "@type": "Answer", "text": "No. Olympus produces FAI packages on the official SAE Rev C forms (or the customer-specified revision when different). We deliver a complete PDF package — Form 1, Form 2, Form 3, balloon drawing, CMM output, material certifications, special-process certifications, and the disposition record for any nonconforming characteristics — bound into a single deliverable." } } ] } ] } ] --- [Home](/) [CNC Milling](/cnc-milling) [CNC Turning](/cnc-turning) [Quality Assurance](/quality-assurance) [CNC Machining Capabilities](/capabilities) [CNC Machining Services](/cnc-machining) [Quality Program](/quality) [Contact Olympus Machining](/contact) [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) [Compliance & Cybersecurity](/compliance) [Privacy Policy](/privacy-policy) [Blog](/blog) [Sitemap](/sitemap) [Pennsylvania CNC Machining](/areas-served/pennsylvania-cnc-machining) [Maryland CNC Machining](/areas-served/maryland-cnc-machining) [Virginia CNC Machining](/areas-served/virginia-cnc-machining) [Delaware CNC Machining](/areas-served/delaware-cnc-machining) [New Jersey CNC Machining](/areas-served/new-jersey-cnc-machining) [New York CNC Machining](/areas-served/new-york-cnc-machining) [Ohio CNC Machining](/areas-served/ohio-cnc-machining) [West Virginia CNC Machining](/areas-served/west-virginia-cnc-machining) [Washington DC CNC Machining](/areas-served/washington-dc-cnc-machining) [North Carolina CNC Machining](/areas-served/north-carolina-cnc-machining) [Aerospace Machining Tolerances Explained](/blog/aerospace-machining-tolerances-explained) [Titanium CNC Machining for Aerospace](/blog/titanium-cnc-machining-aerospace) [Aerospace CNC Machine Shop Near DC/MD](/blog/aerospace-cnc-machine-shop-near-washington-dc-maryland) [Cutting-Edge CNC Shop for Aerospace](/blog/cutting-edge-cnc-machine-shop-aerospace-industry) [Best CNC Machine Shop in Hanover, PA](/blog/best-cnc-machine-shop-hanover-pa) [QMS: Precision, Traceability, Process Control](/blog/quality-management-system-qms-precision-traceability-process-control) [Vet a CNC Shop in Pennsylvania](/blog/vet-cnc-machine-shop-pennsylvania-aerospace-defense-robotics) [CNC Shops in Rural America: Hanover, PA](/blog/cnc-machine-shop-rural-america-hanover-pa) [Aerospace CNC Machining in Pennsylvania](/blog/aerospace-cnc-machining-pennsylvania) [CNC Prototyping in PA](/blog/cnc-prototyping-pa) [CNC Machining in Pennsylvania](/blog/cnc-machining-pennsylvania) [Choosing CNC Machining Vendors](/blog/choosing-machining-vendors-cnc-machining-shop) [CNC Machining for Robotics — Guide](/blog/cnc-machining-for-robotics-automation-guide) [CNC Machining Parts for Robotics](/blog/cnc-machining-for-robotics-automation) [Prototype-to-Production CNC Machining](/blog/prototype-to-production-cnc-machining) [How OEMs Evaluate CNC Machine Shops](/blog/how-oems-evaluate-cnc-machine-shops) [CMM Inspection at Olympus Machining](/blog/cmm-inspection-enhances-quality-and-repeatability-at-olympus-machining) [ITAR & CMMC Level 1 in Precision CNC Machining](/blog/itar-cmmc-level-1-precision-cnc-machining) [Precision CNC Machining in Hanover, PA](/blog/precision-cnc-machining-hanover-pa) [AS9102 First Article Inspection Checklist](/blog/as9102-first-article-inspection-checklist) [AS9102 First Article Inspection](/as9102-first-article-inspection) [AS9102 FAI vs PFAI](/as9102-fai-vs-pfai) [AS9102 Balloon Drawings](/as9102-balloon-drawings) [CMM Inspection Services](/cmm-inspection-services) [Medical-Grade Alloys](/materials/medical-grade-alloys) [CMMC Level 1 Compliance](/compliance/cmmc-level-1) [Olympus vs Xometry](/comparison/olympus-vs-xometry) [Olympus vs Protolabs](/comparison/olympus-vs-protolabs) [Direct Shop vs Marketplace](/comparison/direct-shop-vs-marketplace) [Aerospace & Defense Machining](/industries/aerospace-defense) [Medical Device Machining](/industries/medical-devices) [Firearms & Suppressor Machining](/industries/firearms-suppressors) [Energy & Oil/Gas Machining](/industries/energy-oil-gas) [Philadelphia CNC Machining](/areas-served/philadelphia-cnc-machining) [Pittsburgh CNC Machining](/areas-served/pittsburgh-cnc-machining) [Baltimore CNC Machining](/areas-served/baltimore-cnc-machining) [Titanium CNC Machining](/materials/titanium-cnc-machining) [PEEK 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 Home](/) # AS9102 First Article Inspection (FAI) Guide for CNC Machined Parts AS9102 is the SAE International aerospace standard governing First Article Inspection (FAI) for parts and assemblies delivered to aerospace and defense customers. Olympus Machining LLC — an ITAR-registered, CAGE 9V9P0 precision CNC machine shop in Hanover, Pennsylvania (York County) — produces AS9102 Rev C documentation packages for every qualifying first article we ship. This guide explains what AS9102 requires, walks through Form 1, Form 2, and Form 3, and details the FAI workflow we use on our coordinate measuring machines — the Haas HMM 430 and the Chien Wei CWB-450-CNC. Internal links connect to our [precision CNC machining](/precision-cnc-machining), [CNC milling](/cnc-milling), and [CNC turning](/cnc-turning) capability pages. ## What AS9102 Is and When It Is Required AS9102 (currently Revision C, released August 2023) defines the minimum requirements for documenting that a first production article complies with the engineering drawing, purchase order, and applicable specifications. It applies to parts and assemblies for aerospace, defense, and space programs governed by AS9100 quality management systems. Most prime contractors flow AS9102 down to subtier suppliers contractually — meaning that if a prime requests a first article on your part, an AS9102-conformant FAI package is the deliverable. FAI is required when (1) a part is produced for the first time, (2) the design, tooling, process, or supplier changes, (3) a lapse of two or more years has occurred since the last production run, or (4) the customer specifies it on the purchase order. Common triggers include a revision change to the drawing, a material substitution, a change in the manufacturing facility, or a change in the inspection method. **Rev B vs Rev C key differences:** Revision C clarifies the treatment of digital product definitions (model-based definition, or MBD), expands guidance on partial FAIs (PFAI), and tightens the rules around traceability of special processes. Rev C also formalizes the treatment of additive manufacturing characteristics. Olympus Machining produces FAI packages to the customer-specified revision — most current programs require Rev C. ## Form 1 — Part Number Accountability Form 1 establishes the identity of the part being inspected. It captures the part number, part name, drawing number and revision, serial or lot number, manufacturing process record (router, traveler, or work order number), and whether the FAI is a full FAI or partial FAI (PFAI). For assemblies, Form 1 also lists every sub-component part number and indicates whether each sub-component has its own FAI. Olympus Machining populates Form 1 from the customer purchase order and our internal job traveler. Because we operate under documented procedures with traveler-controlled revision tracking, the Form 1 entries are pulled directly from the work order rather than transcribed by hand — eliminating the most common source of Form 1 rejections (mismatch between part revision on the form and the revision actually built). See the related guide: [Full FAI vs Partial FAI — when each is required](/as9102-fai-vs-pfai). ## Form 2 — Product Accountability for Materials and Special Processes Form 2 documents the raw material certifications and any special processes (heat treat, plating, anodizing, passivation, NDT, welding) applied to the part. Each line item captures the specification (e.g., AMS-QQ-A-250/11 for 6061-T6 plate, or AMS 2700 for stainless passivation), the actual certification number, the name of the supplier or processor, and the date of certification. Olympus Machining maintains material certifications and process certifications in a controlled job folder for every order. For special processes routed to outside vendors — anodizing, plating, heat treat, NDT — we require Nadcap-accredited (where applicable) or customer-approved suppliers, and the certification copies are bound into the FAI package alongside our internally generated documentation. For ITAR-controlled parts, Form 2 also documents the chain of custody from raw material receipt through finished part — supporting the traceability requirements of FAR 52.204-21 and our CMMC Level 1 alignment. ## Form 3 — Characteristic Accountability Form 3 is the dimensional report. Every drawing characteristic — dimension, tolerance, GD&T callout, surface finish, material requirement, and note — is assigned a balloon number on a balloon-annotated drawing. Form 3 then lists, for each balloon: the requirement (nominal and tolerance), the actual measured value, the inspection method (CMM, micrometer, gage pin, vision system), and the accept/reject result. Olympus Machining produces balloon drawings using High QA and equivalent inspection planning software. The balloon drawing becomes the master reference for Form 3 entries, ensuring that no characteristic is missed and that balloon numbering is consistent between the drawing and the form. For a deeper walkthrough of the balloon-numbering process, see [How Balloon Drawings Work for AS9102 Form 3](/as9102-balloon-drawings). ## Olympus Machining FAI Workflow 1. **1\. Balloon the drawing** Every callout on the customer print is assigned a unique balloon number using High QA. The balloon drawing is reviewed against the engineering drawing for completeness before any chips are cut. 2. **2\. Build the CMM program** Inspection programs are written for the Haas HMM 430 (3-axis CMM) and the Chien Wei CWB-450-CNC (CNC CMM with rotary table) to capture every dimensional characteristic on the balloon drawing. 3. **3\. Machine the first article** The part is machined on our 3-, 4-, or 5-axis CNC mills or live-tooling lathes using the documented setup that will be used for production. The first piece off the setup is the first article. 4. **4\. Run CMM and supplemental inspection** The CMM program is executed; non-CMM characteristics (threads, surface finish, visual notes) are inspected with appropriate hand tools, gages, and visual references. 5. **5\. Populate Form 1, Form 2, Form 3** Form 1 is pulled from the traveler; Form 2 from the controlled certification folder; Form 3 from the CMM output and supplemental inspection records. 6. **6\. Internal review and customer delivery** The FAI package is reviewed by our quality lead before being released. The customer receives a PDF package — and, for ITAR programs, the package is delivered through controlled channels per the customer's program security requirements. ## Common FAI Rejection Reasons (and How We Prevent Them) Form 1 part revision mismatch Form 1 fields are auto-populated from the work order traveler — no manual transcription. Missing material certification on Form 2 Material cert is uploaded to the controlled job folder at the time of receiving inspection. The FAI package will not release without it. Balloon numbers on Form 3 don't match the drawing Balloon drawing is the single source of truth for balloon numbering — Form 3 is generated from it. Missing characteristics (notes, surface finish, GD&T datums) Drawing review is performed before ballooning. Notes and datum callouts are explicitly balloon-numbered, not assumed. Inspection method not stated or not appropriate Inspection method is selected per characteristic during CMM programming and recorded in the inspection plan. Out-of-tolerance condition shipped without disposition Any out-of-tolerance characteristic triggers an internal MRB review. The part is not shipped until disposition (rework, use-as-is with customer concurrence, or scrap) is documented. ## AS9102 Form Templates Blank AS9102 Rev C Form 1, Form 2, and Form 3 templates are published by SAE International. Customers and engineering teams should download the official templates directly from SAE to ensure they are using the current revision: [SAE AS9102C standard and forms](https://www.sae.org/standards/content/as9102c/) Olympus Machining produces FAI packages on the official SAE Rev C forms (or the customer-specified revision when different). Customers do not need to supply blank templates — we provide the completed package. ## Printable Pre-Submission FAI Checklist Engineering and procurement teams can use this checklist before submitting a part for first-article. Each item maps to a section of the AS9102 Rev C package Olympus delivers; missing inputs are the single largest cause of FAI re-work. Released drawing PDF at the revision being machined (no markups, no 'preliminary' watermarks). 3D model (STEP or IGES) matching the drawing revision — required for MBD characteristics. Material specification on the drawing or PO (e.g., AMS 4928 Ti-6Al-4V bar, 6061-T6 plate AMS-QQ-A-250/11). Outside-process specifications called out where applicable (heat treat, anodize Type II/III, passivation per AMS 2700, NDT method). Key Characteristics (KCs) clearly flagged on the drawing, with measurement method and frequency identified. PO clearly states FAI required (full or partial), revision of AS9102 (Rev C default), and any deviation from standard form. If PFAI: prior FAI report number provided, plus the list of characteristics affected by the change. Customer-specific quality clauses identified (e.g., AS9100 flow-down, Boeing D6-XXX, Lockheed QCS-001, ITAR). Source-inspection or government-source-inspection requirements identified at quote stage, not post-machining. Acceptable surface finish callouts for areas not explicitly noted (default per ASME Y14.36 or customer spec). Marking requirements specified (laser, ink stamp, vibro-peen) with location and content. Packaging and preservation callouts specified (corrosion protection, individual bagging, MIL-STD-2073 if applicable). Browser print preview ("Ctrl/Cmd + P") produces a one-page hand-off checklist for engineering review meetings. ## AS9102 First Article Inspection FAQ ### When is an AS9102 First Article Inspection required? ### What is the difference between a full FAI and a Partial FAI (PFAI)? ### What revision of AS9102 does Olympus produce packages to? ### Who issues the AS9102 standard? ### What information does Form 1 capture? ### What information does Form 2 capture? ### What information does Form 3 capture? ### Do drawing notes need to be ballooned on Form 3? ### What inspection equipment does Olympus use for FAI? ### How long does FAI take to complete? ### How does Olympus handle out-of-tolerance characteristics found during FAI? ### Does the customer need to provide blank AS9102 templates? ## Request FAI on Your Next Order Submit your drawing along with a note that you require an AS9102 first article inspection. We will quote the FAI as a separate line item with a clear scope. [Submit a Drawing](/#submission) ## Related AS9102 Resources - • [Full FAI vs Partial FAI: When You Need Each](/as9102-fai-vs-pfai) - • [How Balloon Drawings Work for AS9102 Form 3](/as9102-balloon-drawings) - • [CMM Inspection Services for Aerospace Parts (Haas HMM 430)](/cmm-inspection-services) - • [Quality Assurance and Inspection Capabilities](/quality-assurance) - • [CMMC Level 1 Compliance for DoD CNC Suppliers](/compliance/cmmc-level-1) [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. Olympus Machining LLC · 639 Frederick St, Suite 1 · Hanover, PA 17331 · (717) 634-5094 Explore all [areas served, industries, and capabilities →](/sitemap) © 2026 All rights reserved.[Admin](/auth) [Compliance & Cybersecurity](/compliance)[Privacy Policy](/privacy-policy)[Sitemap](/sitemap) ITAR-aligned internal controls. Cybersecurity practices aligned with CMMC Level 1 (FAR 52.204-21).