First Article Inspection (FAI)
Before you let them build ten thousand of these. We measure the first units off real production tooling against your own drawings.
1,200+
Completed
24h
Deployment
100-1000x
ROI / Impact
62%
Pass Rate
Understanding the Service
What Is First Article Inspection?
You approved a sample a technician made slowly, by hand, to impress you. The run is made fast, on production tooling, by whoever is on shift. FAI checks the first 5-20 units off that tooling — every critical dimension against your drawings with calibrated instruments, plus material, finish and color against the approved sample.
A client approved a prototype that looked perfect. Mass production revealed a 0.8mm dimensional error invisible to the eye but critical for product fit. FAI on the first 5 production units would have caught it before 10,000 units were produced. The rework cost $85,000.
James Liu
Founder & CEO
Our Protocol
What Our Inspector Checks
Every checkpoint verified on every inspection.
Every critical dimension measured vs. engineering drawings
Tooling condition assessment
Material composition verification
Color matching verification
Surface finish and golden sample comparison
Labeling and marking accuracy
Functional testing of first production units
Packaging prototype verification
Assembly fit and tolerance checks
Production process capability assessment
Use Cases
When You Need This Service
New product launches (prototype to production transition)
New tooling or mold changes
Specification changes on existing products
High-precision products with tight tolerances
Safety-critical components
Process
How It Works
From booking to report in 5 simple steps.
01
Schedule at First Production Run
Book when factory produces first 5-20 units with actual production tooling.
02
Dimensional Verification
Every critical dimension measured with calibrated instruments vs. drawings.
03
Material & Finish Check
Material composition, surface finish, and color verified against specifications.
04
Functional Testing
Units tested for all functional requirements under production conditions.
05
Approval or Correction
Clear pass/fail with detailed corrective actions before mass production continues.
From $268/day — Validate before mass production
Money-back commitmentDeliverables
What You Receive
FAI dimensional report with measurement data
Material verification results
Functional test results
Golden sample comparison photos
Pass/Fail recommendation
Corrective action plan if needed
Inspection Report
PASSED232 000
PASS
132
FAIL
156
PENDING
Key findings
Dimensional variance — 2 units exceeded ±0.3 mm tolerance on housing width. Classified as Major per ISO 2859-1.
All functional and material tests passed on the first 5 golden-sample units. Approved to proceed to mass production.
Common Concerns
Honest Answers to Tough Questions
Prototypes are made with care; production units are made for speed. Different tooling, a different materials batch, different hands. FAI is the check that what you approved is what the line can actually reproduce.
No. PSI samples finished goods against AQL limits once production is complete; FAI examines the very first 5-20 units off the line — before mass production runs — to confirm the tooling, materials, and process actually reproduce your approved prototype. It's a gate you pass through early, not a final check.
FAI caught a 0.3mm variance that would have affected 50,000 brake pads. Critical for safety.
— Quality Director, Automotive Parts Importer
FAQ
Frequently Asked Questions
Typically 5-20 first production units. The number depends on product complexity and your specification requirements.
As soon as the factory produces its first 5-20 units on actual production tooling — before the full run starts. Catching a tooling or material deviation at unit 5 is dramatically cheaper than discovering it after 10,000 units have been made.
No — they're separate checkpoints. PSI samples finished goods against AQL limits once production is complete, while FAI validates the very first production units up front. Many importers bundle FAI, DUPRO, and PSI together for full-run coverage on a new product launch.
You receive a clear fail determination with the exact deviations and a corrective-action plan before mass production continues. You can hold the run, have the factory adjust tooling or materials, and re-inspect once the fix is in — stopping a defect at the source instead of the whole container.
What's Next?
Follow FAI with DUPRO at 30% and PSI at 100% for new product launches.
Download sample report
First-time importer?See our starter guide
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