How much does it cost · first article inspection
For a moderately complex machined part (30 to 50 characteristics), a full first article inspection (FAI) typically adds $200 to $800 to the first article; it is a one-time cost amortized over the production run (MakerStage, February 2026). Mavlon, which publishes FAI software, estimates 6 hours and $350 to $500 of labor for a medium-complexity part with 25 to 50 characteristics (Mavlon, March 2026). When the buyer requests a first article, RFQdecoder adds a “first article report” line: the published cost of a full report of 30 to 50 characteristics, paid once for the order and spread over the quantity ordered. Over 100 parts, $200 to $800 comes to $2 to $8 per part.
MakerStage’s inspection guide gives an order of magnitude for a machined part: a full FAI on a moderately complex part, with 30 to 50 characteristics, typically adds $200 to $800 to the first article. The source states that this is a one-time cost amortized over the production run, and that a partial (delta) FAI after a revision change costs less (source: MakerStage, February 2026).
Mavlon, which publishes FAI preparation software, breaks down the work for a medium-complexity part (25 to 50 characteristics): 3 h of Form 3 preparation, 2 h of inspection and 1 h of documentation, i.e. 6 h and $350 to $500 of labor. The quality engineer is costed at $60/h and the inspector at $50/h. For a complex part (50 to more than 100 characteristics), Mavlon gives 11.5 h and $650 to $1,200 (source: Mavlon, March 2026). According to Ideagen, an AS9102 report completed manually can take a full day per part (source: Ideagen, July 2026).
What RFQdecoder does. When the buyer requests a first article, the tool adds a “first article report” line. It carries the cost published by MakerStage for a full report of 30 to 50 characteristics (source: MakerStage, February 2026). This cost is paid once for the order, then spread over the quantity ordered.
An AS9102 first article report rests on three forms: Form 1 (Part Number Accountability), Form 2 (Product Accountability) and Form 3 (Characteristic Accountability) (source: Criterion Precision, February 2026). Form 2 accounts for all material and process specifications, along with the special processes and functional tests defined as design requirements (source: Ideagen, July 2026). Form 3 lists every dimensioned characteristic on the drawing (dimensions, tolerances, GD&T callouts, surface finishes, notes) with its nominal value, tolerance, measured value and pass or fail status (source: MakerStage, February 2026).
Difference from in-process inspection. The first article validates that the product realization processes can produce parts that meet the design requirements (source: IAQG FAQ, December 2014). In-process inspection monitors critical dimensions during production to catch drift, with first-piece verification on every setup; production lots of more than 50 parts typically use AQL sampling (source: MakerStage, February 2026). The first article covers every characteristic on the drawing, once, unless an event requires it to be repeated; in-process inspection covers critical dimensions and is repeated at every setup and every lot.
In automotive: PPAP and initial sample reports. PPAP (Production Part Approval Process) is mainly used in the automotive industry, with five levels of documentation, whereas the AS9102 FAI, the aerospace and defense standard, has a single format (source: Criterion Precision, February 2026). Level 1 is the Part Submission Warrant (PSW) only; Level 3 includes the PSW, product samples and complete supporting data; at Level 5, the complete data remains available for review at the supplier’s manufacturing location (source: InspectionXpert, October 2019). For the initial sample inspection report (Erstmusterprüfbericht), Q-Tech Roding states that the forms of VDA Volume 2 (Verband der Automobilindustrie) or those of the AIAG PPAP are used, depending on the order (source: Q-Tech Roding, May 2021).
According to SAE, as cited by Ideagen, a first article is required for the first production run of a new product, after a design change, after a change of material or source, when more than 2 years have passed since the part was last produced, and after a change in process, tools or location (source: Ideagen, July 2026).
The Q2A quality clause of Lockheed Martin Aeronautics, which refers to AS9102, requires a partial or full FAI for any change affecting the form, fit, function, safety or reliability of the part, including a change to the program of a numerically controlled machine or of coordinate measuring equipment, and after a lapse in production of more than two years. A partial FAI there requires a single part, to show that the change had no impact (source: Lockheed Martin, June 2016).
For a production lapse of 2 years or more, the IAQG FAQ answers that a full FAI is normally required; a partial FAI remains possible if the FAI procedure describes it and the reason is recorded in field 14 of Form 1, which may be subject to customer approval (source: IAQG FAQ, December 2014).
Assumptions (chosen for illustration, not taken from a source): an order of 10, then 100, then 1,000 parts; a price of $25.00 per part excluding the first article report; a single first article report requested for the order.
Published value used: $200 to $800 for a full FAI of 30 to 50 characteristics, a one-time cost amortized over the run (source: MakerStage, February 2026). The amount is kept in dollars, as in the source.
The cost of the report does not change with quantity: only its share per part falls. On a small order it can exceed the price of the part itself, as here at 10 parts with the upper bound ($80.00 against $25.00).
For a moderately complex part with 30 to 50 characteristics, MakerStage publishes $200 to $800 added to the first article, a one-time cost amortized over the run (February 2026). Mavlon estimates $350 to $500 of labor for a part with 25 to 50 characteristics (March 2026).
Mavlon counts 6 hours for a medium-complexity part (3 h of preparation, 2 h of inspection, 1 h of documentation) and 11.5 hours for a complex part (March 2026). According to Ideagen, an AS9102 report completed manually can take a full day per part (July 2026).
In the documents consulted, yes: the Lockheed Martin Q2A clause requires a partial or full FAI after a lapse in production of more than two years (June 2016), and the IAQG FAQ states that a full FAI is normally required after 2 years or more; a partial FAI remains possible if it is justified and, where applicable, approved by the customer.
The AS9102 FAI is the aerospace and defense format, with three forms. PPAP is mainly used in automotive and has five submission levels, for example the PSW alone at Level 1, and the PSW with samples and complete supporting data at Level 3 (Criterion Precision, February 2026; InspectionXpert, October 2019). For the initial sample report (Erstmusterprüfbericht), the forms are those of VDA Volume 2 or of the AIAG PPAP, depending on the order (Q-Tech Roding, May 2021).
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