AS9102 Form 3 Builder.
Build characteristic accountability forms for aerospace First Article Inspection. Add dimensions, paste measurements, get pass/fail verdicts. Export to PDF for OEM submission.
FAI Header Information
| Char # | Characteristic / Feature | Requirement | Tol + | Tol − | Measured | Method | Result |
|---|
metricmech.com
| Part Number | — | Revision | — |
| Part Name | — | ||
| Drawing Number | — | FAI Report No. | — |
| Supplier | — | Customer / OEM | — |
| Inspector | — | Date | — |
| Char # | Characteristic / Feature | Requirement | Tol + | Tol − | Measured | Method | Result |
|---|
|
0
Total Characteristics
|
0
Pass
|
0
Fail
|
What is AS9102 Form 3?
AS9102 Rev C Form 3 is the Characteristic Accountability section of the aerospace First Article Inspection (FAI) report. It documents every dimension, GD&T callout, material spec, and surface finish on the drawing — with the actual measured value and pass/fail status.
Form 3 is the most data-intensive form in the AS9102 family. Forms 1 (Part Number Accountability) and 2 (Product Accountability) cover identification; Form 3 is where the engineering verification lives.
What Goes on AS9102 Form 3?
Every "balloon" on your drawing becomes one row on Form 3:
- Characteristic Number (matches drawing balloon)
- Reference Location (drawing zone, sheet, view)
- Characteristic / Designator (e.g., "Length", "Position", "Surface Finish Ra")
- Requirement (nominal + tolerance, e.g., 50.00 ±0.05)
- Results / Measured Value (actual measurement)
- Inspection Method (Caliper, CMM, Surface Plate, Visual...)
- Pass / Fail status
Common AS9102 Mistakes That Cause Rejection
- Missing balloons — every drawing callout must be on Form 3, including notes, material spec, heat treatment, surface treatment, and any GD&T frame.
- Stale drawing revision — Form 3 must reference the released drawing rev that was machined.
- Inspection method gaps — "Visual" is rarely acceptable for dimensional features. Use measurable methods.
- No bias / measurement uncertainty — for tight tolerances, attach a Gauge R&R study.
- Inconsistent units — drawing in metric, Form 3 in imperial. Use the drawing's units.
Worked Example: A Simple Bracket
For a 50 × 25 × 6 aluminum bracket with 4× ⌀5 holes:
- Length 50.000 ±0.10, measured 50.04 (Caliper) → PASS
- Width 25.000 ±0.05, measured 24.98 (Micrometer) → PASS
- Thickness 6.000 ±0.05, measured 6.02 (Micrometer) → PASS
- Hole ⌀ 5.000 ±0.05, measured 5.012 avg (Pin Gauge) → PASS
- Hole position true position ⌀0.10, measured ⌀0.08 (CMM) → PASS
- Surface Finish Ra 1.6 µm, measured 1.4 µm (Profilometer) → PASS
- Material AMS 4117 verified → PASS (Cert # attached)
- Heat treatment T6 hardness HRB 75±5, measured HRB 78 → PASS
That's 8 characteristics for a simple bracket. Aerospace assemblies typically have 30-100 balloons.
Related Tools and Workflow
Build process capability evidence with Cp/Cpk studies and verify your measurement system via Gauge R&R. For position tolerances, use the Position Tolerance calculator. Continue to full PPAP submission for automotive customers, or use the FAI data directly for aerospace AS9100 audits.