FAI templates

FAI report templates, ready to load.

Load a template into the builder or download the characteristic set as JSON. These are starter records, not controlled forms. Replace the example characteristics with the requirements from the drawing.

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Forms 1–3

AS9102 full FAI

Full first article with part, material, process and characteristic forms. Starts from a typical L-bar busbar.

Balloon	Characteristic	Limits
1	Overall flat length	212.69468914507712 / 213.69468914507712 mm
2	Bar width	39.7 / 40.3 mm
3	Bar thickness	5.9 / 6.1 mm
4	Hole Ø9 position X	19.8 / 20.2 mm
5	Hole Ø9 position Y	19.8 / 20.2 mm

Use when a new part or a major change requires a complete first article inspection.

Dimensional results

PPAP dimensional results

Dimensional results sheet for a production part approval submission, with five starter characteristics.

Balloon	Characteristic	Limits
1	Overall length	119.7 / 120.3 mm
2	Bar width	39.8 / 40.2 mm
3	Bar thickness	5.9 / 6.1 mm
4	Hole diameter	8.9 / 9.1 mm
5	Hole position	19.7 / 20.3 mm

PPAP also needs process flow, PFMEA, control plan, MSA and capability evidence.

Forms 1 and 3

Delta FAI

A short-form delta FAI with baseline part and revision fields for a change that affects only selected characteristics.

Balloon	Characteristic	Limits
1	Changed dimension	79.7 / 80.3 mm
2	Changed hole position	14.8 / 15.2 mm
3	Changed bend angle	89.5 / 90.5 deg

Record the baseline part, revision and date, and state why the delta FAI is being performed.

Batch record

Batch inspection record

Simple batch record for a production lot, with drawing, lot and sample values.

Balloon	Characteristic	Limits
1	Length	199.7 / 200.3 mm
2	Width	39.8 / 40.2 mm
3	Hole diameter	9.9 / 10.1 mm
4	Bend angle	89.5 / 90.5 deg

Use for routine lot inspection; it is not a substitute for a full FAI.

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