PCB Only
Board dimensions, copper structure, materials, stack-up, electrical tests, and surface finish verification.
Quality Assurance
First Article Inspection (FAI) for PCB & PCBA
APTPCB performs First Article Inspection (FAI) on new and changed projects to make sure the boards we build for you match your design before we move into full volume. FAI is an integrated step in our PCB & PCBA production process—not a separate paid service.
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First Article Inspection: The Gate Between Trial and Mass Production
APTPCB is a PCB manufacturing and PCB assembly (PCBA) provider focused on stable quality and reliable mass production. As part of our standard quality workflow, we perform First Article Inspection (FAI) on new and changed projects to make sure the boards we build for you match your design before we move into full volume.
FAI is not a standalone service we sell separately. It is an integrated step in our PCB & PCBA production process to help you reduce risk on new designs and revisions, shorten approval time with your own customers, and build a stable, repeatable production baseline.
How First Article Inspection Fits into Our PCB & PCBA Process
Whenever you start a new project or major change with APTPCB, your order goes through a structured flow:
- DFM / DFA review – we check manufacturability and assembly feasibility.
- Tooling & process setup – stack-up, materials, programs, stencils, fixtures.
- Trial build / first lot – we fabricate and (if needed) assemble your first batch.
- First Article Inspection (FAI) – we verify the first piece against your requirements.
- Customer approval – you review the FAI results and samples.
- Stable mass production – only after FAI is passed and confirmed.
FAI is the gate between trial and mass production. It gives both sides confidence that the production process is correctly set, the actual PCB/PCBA matches the drawing, BOM and specs, and we can repeat the same quality across larger quantities.
When We Perform FAI on Your PCB / PCBA Order
We apply First Article Inspection in situations where quality risk is naturally higher, for example:
- New PCB or PCBA design (NPI)
- Major design revision (layout changes, stack-up changes, new components)
- Change of material or key process (laminate, surface finish, soldering process, etc.)
- New tooling or new production line for your project
- Customer-specified FAI / FAIR requirement (e.g. aerospace, automotive, industrial projects)
In many cases we will proactively propose FAI; in others you can specify it as a requirement in your RFQ or PO. For repeat, unchanged orders with stable history, we usually rely on regular process control and final inspection, not a full FAI every time.
What We Check During FAI for PCB Manufacturing
For bare PCB manufacturing, our FAI typically covers:
Board Dimensions & Features:
- Overall board size and outline
- Hole sizes, positions, and tolerances
- Slot dimensions and mechanical cut-outs
- Board thickness (overall and, if required, core / prepreg)
Copper & Layer Structure:
- Trace width and spacing on each critical layer
- Annular ring and land sizes for plated holes
- Layer registration and alignment (inner and outer layers)
- Surface finish type and thickness (ENIG, HASL, immersion silver, etc.)
Materials & Stack-Up:
- Laminate type and Tg as specified
- Copper weight per layer (e.g. 1 oz, 2 oz, etc.)
- Solder mask color, coverage and alignment
- Silkscreen clarity and placement
Electrical & Special Requirements (When Applicable):
- Electrical test: continuity and isolation
- Controlled impedance test results (for high-speed designs)
- Any special tests agreed in advance (peel strength, warpage, etc.)
All findings are documented and linked to your part number and revision, forming the baseline for ongoing PCB production.
What We Check During FAI for PCBA (Assembly)
If you also place PCBA assembly with APTPCB, the First Article Inspection at assembly level focuses on:
Component & BOM Compliance:
- Correct components loaded versus your BOM
- Part number, value, and package verification for key components
- Substitution control as per your approval (if any)
Placement & Orientation:
- Placement accuracy on fine-pitch ICs, BGAs, connectors, etc.
- Polarity and orientation of polarized parts (diodes, electrolytic capacitors, ICs, LEDs, etc.)
- Alignment of connectors, switches and mechanical interfacing parts
Solder Quality (with AOI & Visual):
- Solder joint shape and coverage on SMT and THT parts
- Bridges, tombstones, insufficient or excess solder
- Rework areas, if any, checked against standards
Basic Electrical / Functional Checks (If in Scope):
- Power-on and basic current consumption check
- Simple functional checks (e.g. LEDs, buttons, communication ping)
- Or a defined Functional Test if you provide or request a test spec
After FAI approval, the same assembly programs, stencil, reflow profile and test flow are used for mass production, ensuring consistency across all shipments.
First Article Inspection Report (FAIR) You Receive
You don't just receive a 'good sample'; you get documentation you can use internally or with your own customers.
A typical FAI / FAIR package from APTPCB may include:
- Part number and revision identification
- Reference to drawings, specs, and BOM used
- List of measured characteristics (dimensions, thickness, key features) with results
- Material and process details (laminate, copper weight, surface finish, solder process, etc.)
- Photos of the board / assembly and key areas
- Electrical or functional test results (when part of FAI scope)
If you need a specific format (e.g. AS9102-style forms or a customer template), we can prepare the FAI package according to that structure as long as it's clearly defined at order stage.
What This Means for You as a Customer
By choosing a PCB manufacturer and PCB assembly partner that embeds FAI into the process, you get practical advantages:
Lower Risk on New Projects:
- Issues are found and fixed on the first build, not after several lots
- Design or documentation gaps are surfaced early
Easier Internal & Customer Approval:
- Clear, structured FAI documentation you can attach to your own quality records
- Faster sign-off with engineering, quality and key accounts
More Stable Mass Production:
- Once FAI is approved, production runs follow the same validated process
- Changes that require a new FAI can be clearly tracked and discussed
Stronger Message to Your Own Market:
- You can confidently tell your customers that your boards are manufactured and assembled by a professional PCB manufacturing & PCB assembly company, with First Article Inspection built in for new designs and changes.
- This directly supports your own quality positioning and brand trust.
FAI Scope & Coverage
PCBA Assembly
Component compliance, placement accuracy, solder quality, and basic functional checks.
Documentation
Comprehensive FAIR report with measurements, photos, test results, and material details.
Custom Formats
AS9102 forms, customer templates, or specific documentation requirements as needed.
Risk Reduction
Early detection of design or process issues before mass production ramp.
Production Baseline
Validated process becomes the standard for all subsequent production runs.
How to Request FAI with Your PCB / PCBA Order
You don't need to manage FAI as a separate 'service'. Simply:
- Send your RFQ with Gerber / CAD data, BOM (for PCBA), drawings and key specs
- Tell us your FAI expectations – PCB only, or PCB + PCBA; required documents / format (if any); any special characteristics to highlight
- We will include FAI planning into our quotation and production plan for new or changed projects.
Partner with APTPCB for PCB & PCBA with Built-In First Article Inspection
If you are preparing to launch a new board or move an existing one to a new supplier, and you want reliable PCB manufacturing, PCB assembly, and built-in First Article Inspection, APTPCB is ready to support you from prototype through mass production.
Our integrated FAI process ensures that your first production run is not a gamble—it's a validated, documented step toward stable, repeatable quality. Contact us today to discuss your PCB and PCBA needs.
Get Started with First Article Inspection
Share your design files, BOM, and FAI requirements. Our team will include FAI planning in your quotation and ensure your first production run is validated and documented.