Releasing production without a solid first article inspection injection molding package is how line-down starts on week one. FAI proves the process — not just that T1 samples looked good on a bench.
What FAI should include for molded parts
- Full dimension report on drawing CTQs
- Material certificate of conformance (grade, lot)
- Process record: machine, mold version, cycle parameters
- Cosmetic sign-off against agreed master
- Corrective action closure on any out-of-spec dims
Align with broader quality scope in our PPAP / FAI guide.
FAI vs T1 — buyers confuse them
| Event | Purpose |
|---|---|
| T1 / T0 samples | Tool tryout, design validation |
| FAI | Production process capability sign-off |
Approving T1 does not replace FAI at production setup — different machine, operator, or resin lot can shift dimensions.
When to reject FAI
- CTQ out of band without approved deviation
- Material lot undocumented
- Cosmetic class failures on A surfaces
- Missing insert torque or weld test records when specified
FAQ
Is AS9102 required for industrial OEM?
Only if your customer mandates it; many industrial programs use a simplified dimensional FAI.
Who pays for re-FAI after engineering change?
Define in PO — customer-driven changes usually customer-funded.
Next step: Define FAI scope in your next contract manufacturing RFQ.