First Article Inspection in Sheet Metal Manufacturing
First Article Inspection (FAI) is a critical quality control process in sheet metal manufacturing, serving as the bridge between design intent and full-scale production. It is the first formal verification that a manufactured part meets all specified requirements before mass production begins. When performed correctly, FAI helps prevent costly errors, reduces scrap, and builds confidence between manufacturers and customers.
What Is First Article Inspection?
First Article Inspection is the detailed examination of an initial production part to confirm that it conforms to engineering drawings, specifications, and customer requirements. In sheet metal fabrication, this includes verifying dimensions, material type and thickness, bend angles, hole locations, surface finish, and any secondary operations such as welding, hardware insertion, or coating.
The “first article” is typically produced using the same tooling, machines, programs, and processes intended for full production. This ensures that the inspection reflects real manufacturing conditions rather than a one-off prototype.
Why FAI Matters in Sheet Metal
Sheet metal parts often have tight tolerances, complex bends, and multiple features that must align perfectly during assembly. Even small deviations—such as incorrect bend radii or hole misalignment—can cause fit-up issues downstream. FAI catches these issues early, before hundreds or thousands of parts are produced incorrectly.
FAI is especially important when:
Launching a new part or product
Making changes to design, tooling, or manufacturing processes
Using new materials or suppliers
Restarting production after an extended pause
By identifying problems at the beginning, manufacturers can make corrections quickly and at a much lower cost.
Key Elements of Sheet Metal FAI
A comprehensive First Article Inspection typically includes:
Dimensional Verification: Measuring critical and non-critical dimensions using calipers, height gauges, CMMs, or laser scanners.
Material Verification: Confirming the correct material grade, thickness, and certifications.
Bend and Form Checks: Verifying bend angles, radii, and overall flat pattern accuracy.
Feature Inspection: Checking hole sizes, locations, slots, cutouts, and formed features.
Surface Finish and Appearance: Inspecting for scratches, burrs, sharp edges, or coating defects.
Functional Fit: Ensuring the part fits properly with mating components or assemblies.
All results are typically documented in an FAI report, which may include ballooned drawings, measurement data, and pass/fail criteria.
Benefits of a Strong FAI Process
Implementing a robust FAI process delivers clear benefits:
Reduced rework and scrap
Faster production ramp-up
Improved product consistency
Better compliance with industry standards such as AS9102 or ISO requirements
Increased customer trust and satisfaction
Conclusion
First Article Inspection is more than a formality—it is a vital step in ensuring quality and reliability in sheet metal manufacturing. By validating the first part before committing to full production, manufacturers can minimize risk, control costs, and deliver parts that meet expectations from the very first run. A disciplined FAI process sets the foundation for successful, repeatable production and long-term customer confidence.