AS9102 Rev C Requirements Explained

I have reviewed dozens of FAI packages that were rejected because the quality engineer was still following Rev B practices on a Rev C submission. The differences between revisions are not dramatic, but the ones that exist will get your FAI sent back if you miss them.

This guide covers AS9102 Rev C requirements explained in practical terms: what changed, what stayed the same, and what auditors actually look for when they open your package.

AS9102 Rev C (released 2014, still current as of 2026) is the aerospace standard for First Article Inspection. It defines the three-form structure and the rules for when and how FAI must be performed. If you are new to the three-form structure, we cover each form in detail in our guide on AS9102 Form 1 vs Form 2 vs Form 3 explained.

AS9102 Rev C Requirements Explained: The Three Forms

Form 1: Part Number Accountability

Form 1 is the cover sheet. It identifies the part (part number, name, serial number), the drawing (drawing number, revision level), the organization performing the FAI, and the overall result (pass/fail). It also captures whether the FAI is full or partial, and if partial, the justification.

The fields that cause the most trouble on Form 1 are Fields 15-18, which apply to assemblies. If the part number in Field 1 is an assembly, you must list every sub-component with its part number, description, type (detail, sub-assembly, software, COTS), and the FAI status of each sub-component. Missing any sub-component from this list is an audit finding.

Form 2: Product Accountability

Form 2 documents the materials and processes used to manufacture the first article. Every raw material must be listed with its specification (AMS 4078, AMS 2770, etc.), supplier, and certification reference. Every special process (heat treatment, surface treatment, non-destructive testing) must be listed with the processor name, specification, and certification.

The most common Form 2 mistake is missing materials. On a bracket made from Al 7075-T6 that gets chemically converted and anodized, Form 2 needs: the aluminum raw material with mill certificate, the chemical conversion with processor certification, and the anodize with processor certification. If the anodize is subcontracted to an outside vendor, their NADCAP certification should be referenced.

Form 3: Characteristic Accountability

Form 3 is where 80% of the labor goes. Every dimensional and geometric characteristic on the drawing gets a row with the requirement (what the drawing says), the actual result (what was measured), and the status (pass/fail). On a complex part, Form 3 can have 50 to 100+ rows.

The preparation of Form 3, building the "Drawing Says" side before any measurement happens, is the most time-consuming step in the entire FAI process. We cover the preparation process in detail in our guide on how to pre-populate AS9102 Form 3 from a drawing.

REV C STILL MEANS EVERY CHARACTERISTIC ACCOUNTED FOR

AS9102 Rev C didn't make Form 3 any shorter. Mavlon captures and numbers every characteristic to the standard, automatically.

Bring your hardest drawing. Watch it become a Form 3 live.

What Changed from Rev B to Rev C

Change 1: Partial FAI Clarification

Rev B was vague about when a partial FAI was acceptable. Quality engineers and their customers frequently disagreed about whether a partial FAI was appropriate for a given situation. Rev C explicitly defines the conditions.

A partial FAI is allowed when:

A design change affects only some characteristics. For example, the customer revises two dimensions on Sheet 3 of a 7-sheet drawing. Only those two characteristics (and any characteristics affected by the change, such as GD&T callouts referencing the same features) need re-inspection. All other characteristics carry forward from the previous full FAI.

An engineering change modifies specific features. A material change from Al 7075-T6 to Al 7075-T73 affects Form 2 and any Form 3 characteristics related to material properties, but does not require re-inspection of dimensional characteristics that are unaffected by the material change.

A minor process adjustment impacts limited characteristics. A tooling change that affects only specific features allows a partial FAI for those features. Unchanged features carry forward.

The key documentation requirement in Rev C: your Form 1 must clearly state "Partial" with a documented justification in the designated field.

Your Form 3 must include ALL characteristics, not just the re-inspected ones. Carried-forward characteristics must reference the previous FAI report number and the previously recorded actual values. If you only include the re-inspected rows, the FAI appears incomplete and will be rejected.

We cover partial vs full FAI in more depth in our guide on AS9102 partial FAI vs full FAI requirements.

Change 2: First Production Run Definition

Rev C clarifies that FAI must be performed on parts representative of the "first production run." This explicitly excludes:

Prototype parts. If your shop makes a prototype run to validate the design before committing to production tooling, those prototype parts cannot be used for FAI. The FAI must be performed on parts made using the production process.

Parts manufactured using non-production methods. If production will run on a 5-axis CNC but the first parts were made on a 3-axis machine with a different setup, those parts do not qualify for FAI.

Parts made with non-production tooling. If you plan to use a dedicated fixture for production but the first parts were made with a temporary setup, the FAI must wait until the production fixture is ready.

This matters practically because some shops try to combine the prototype validation and FAI into one step to save time. Rev C says you cannot. The FAI must reflect the actual production process, tooling, and methods.

Change 3: Assembly FAI Requirements

Rev C added clarity around assembly-level FAI that was ambiguous in Rev B:

The assembly FAI must verify characteristics specified on the assembly drawing. This means assembly-level dimensions, gap/flush requirements, fastener torque values, and any other inspectable characteristics shown on the assembly drawing.

Component-level FAIs for all sub-parts must be completed before the assembly-level FAI can be approved. You cannot approve an assembly FAI if any sub-component FAI is outstanding.

Form 1 Fields 15-18 must list all sub-components with their FAI status. Each sub-component needs its part number, description, type, serial number (if applicable), and FAI report reference.

Which of these steps current FAI software automates, and which it leaves to you, is compared tool by tool in our buyer guide.

Change 4: Documentation and Traceability

Rev C strengthened the traceability requirement. Every row in Form 3 must be traceable to a specific requirement in the design documentation. Practically, this means:

Every characteristic must have a reference location. The reviewer must be able to find each characteristic on the drawing within seconds. If your Form 3 says "Characteristic 23: 62.0 +/-0.1mm" but does not indicate "Sheet 3, Section A-A," the reviewer has to hunt through 7 sheets to find it. That delays approval and may result in a traceability finding.

Every tolerance must have a documented source. If a tolerance is derived from a blanket standard (ISO 2768mk) or a general note (Boeing Note 8N), the source must be documented in the Form 3 notes column. We cover tolerance sourcing in detail in our guide on AS9102 Form 3 tolerance source for untoleranced dimensions.

Characteristic numbering must be consistent and logical. The reviewer must be able to follow the numbering scheme without confusion. We cover numbering approaches in our guide on AS9102 Form 3 characteristic numbering rules.

What Auditors Actually Look for in a Rev C FAI

I have spoken with quality engineers at GE Aerospace, Collins Aerospace, Mahindra Aerostructures, and Sansera Engineering about what causes FAI rejections. The pattern is consistent across all of them.

Form 1: Completeness Check

Auditors scan every field on Form 1 for blanks. The most common findings:

Missing or incorrect drawing revision. The drawing was revised between when the FAI was started and when it was submitted. The Form 1 still shows the old revision.

Missing partial FAI justification. The "Partial" box is checked but the justification field is empty or says only "Drawing changed." Rev C requires specific documentation: which characteristics changed, which drawing revision introduced the change, and which characteristics carry forward from which previous FAI report.

Incomplete sub-component listing on assemblies. One or more sub-parts are missing from Fields 15-18. This is especially common when the assembly uses standard catalog hardware (AN, MS fasteners) that the quality engineer does not think to list.

Form 2: Material and Process Traceability

Auditors check that every material and process specification on the drawing has a corresponding entry on Form 2 with a valid certification reference.

Material specification mismatch. The drawing calls out AMS 4078 (Al 7075-T6 sheet) but Form 2 lists AMS 4050 (Al 7075-T6 plate). Both are 7075-T6 but different product forms. The auditor flags the mismatch.

Missing special process certifications. The drawing specifies "Anodize per MIL-A-8625 Type II Class 1." Form 2 lists the anodize vendor but does not reference their process certification or NADCAP accreditation.

Missing sub-tier certifications. The raw material was purchased from a distributor, but the mill certificate is from the original manufacturer. The traceability chain from distributor to mill to material spec must be documented.

Form 3: Characteristic Completeness

This is where most rejections occur. Auditors compare your Form 3 against the drawing and look for gaps.

Missing untoleranced dimensions. The drawing has 30 dimensions without explicit tolerances. If the general notes specify ISO 2768mk, all 30 need Form 3 rows with the correct size-dependent tolerance applied. Missing any of them is an incomplete FAI.

Missing GD&T from later sheets. After Sheets 1 through 4, auditors specifically check whether callouts from Sheets 5, 6, and 7 are captured. Quality engineers consistently confirm that later-sheet GD&T is the most commonly missed category.

We cover this problem in detail in our guide on commonly missed specs on aerospace drawings.

Fit classes not expanded. The drawing shows "9.0 G6" but the Form 3 row just says "G6" without the expanded limits (9.005 to 9.014mm). The inspector cannot verify the measurement without actual limit values. We cover fit class expansion in our guide on ISO fit class G6 tolerance limits.

Surface class designations missing. Class 1 and Class 2 surface designations for anodization appear on the last sheet and are frequently missed during Form 3 preparation.

Cross-Form Consistency

Auditors check that information is consistent across all three forms. Part number on Form 1 must match the Form 3 header. Material on Form 2 must match the drawing callout referenced in the general notes. Drawing revision must be consistent everywhere. Serial number of the inspected part must appear on all forms.

Inconsistencies between forms suggest carelessness and often trigger a more thorough review of the entire package.

Rev C Compliance Checklist

Before submitting any FAI package, verify:

Form 1: Every field filled in. Partial FAI justified with specific details. Assembly sub-components listed (Fields 15-18). Drawing revision current. Signatures and dates present.

Form 2: Every material listed with specification and certification. Every special process listed with processor and certification. Traceability chain complete from raw material through finished part.

Form 3: Every characteristic from every sheet captured. Untoleranced dimensions have blanket tolerances applied and sourced. Fit classes expanded to actual limits. GD&T captured with full datum references. Reference locations documented for every row.

Designators assigned (Critical, Major, Minor) for every row. Units consistent throughout.

Cross-form: Part number consistent. Drawing revision consistent. Serial number consistent. Material specs match between drawing and Form 2.

Mavlon Pre-Populates Form 3 with Rev C Compliance

Mavlon extracts every characteristic and tags each one with its sheet number, view name, and detail reference. The output is Rev C compliant from the start: every row has a traceable reference location, every tolerance is sourced and documented, every GD&T callout includes its full datum reference, and every fit class is expanded to actual limits.

Bring Your Drawing to a Demo to see a Rev C compliant Form 3 from your drawing.