Glossary

digital ballooning

Digital ballooning is the process of adding numbered callouts to engineering drawings in software to identify and track inspection characteristics.

AS9102 First Article Inspection and Net-Inspect

Digital ballooning is the process of adding numbered balloons or callouts to an engineering drawing using software, so that each dimensional or functional requirement can be uniquely identified, referenced, and tracked in downstream quality and manufacturing systems.

In regulated manufacturing, digital ballooning is commonly applied to drawings used for First Article Inspection (FAI), incoming inspection, in-process inspection, and final inspection. Each requirement on the drawing is assigned a characteristic number inside a balloon. These numbers are then used in inspection reports, measurement records, and nonconformance documentation.

How digital ballooning is used in operations

In practice, digital ballooning typically involves:

Importing a 2D drawing (often PDF) into a ballooning or FAI software tool
Placing numbered balloons next to dimensions, notes, tolerances, and key characteristics
Creating a structured list of characteristics that can be exported to FAIRs, inspection plans, or spreadsheets
Linking each balloon number to actual measurement results and any nonconformance records
Storing the ballooned drawing and characteristic list under document control for revision changes

Digital ballooning tools may integrate with PLM, MES, ERP, or QMS systems so that characteristic data flows into digital FAIRs, electronic inspection plans, and change histories.

What digital ballooning includes and excludes

Digital ballooning typically includes:

Numbering all or selected characteristics on the drawing (dimensions, GD&T, notes, material callouts, surface finish, etc.)
Identifying key or critical characteristics that require special tracking or controls
Generating characteristic data (requirement, tolerance, units, sheet/zone, etc.) for inspection documentation

It does not by itself:

Perform the actual inspections or measurements
Guarantee compliance to standards such as AS9102 or ISO 9001
Replace full PLM or CAD systems, although it may consume their data

Relation to digital FAIRs and AS9102

In aerospace and other regulated industries, digital ballooning is a core step in preparing First Article Inspection Reports (FAIRs), including AS9102-based FAIRs. Balloon numbers from the drawing are mapped to the characteristic lines in the FAIR and then to inspection results. This mapping supports traceability from each drawing requirement to its recorded verification and any subsequent changes or deviations.

Common confusion

Digital ballooning vs. traditional (manual) ballooning: Traditional ballooning is done by hand on printed drawings using pens or stamps. Digital ballooning performs the same conceptual task but in software, enabling data export, integration, and easier revision management.
Digital ballooning vs. FAIR creation: Digital ballooning creates the numbered characteristics and their references. FAIR creation uses those characteristics, together with part, process, and measurement data, to generate the full inspection report.
Digital ballooning vs. model-based definition (MBD): In MBD, the 3D model carries dimensions and tolerances directly. Digital ballooning typically annotates 2D drawings, although some tools also support ballooning on 3D views or derived 2D outputs from MBD models.

Yes, FAI (e.g., AS9102) requirements can be triggered automatically from ERP or MES, but only when business rules, master data, and integrations are well defined and validated. In most brownfield plants this requires careful mapping of part/rev status, routing changes, and supplier data, plus change control, testing, and clear ownership of FAI logic.

Does moving production to a different machine always trigger a delta FAI?

No. Moving production to a different machine does not always trigger a delta FAI by itself. The key question is whether the change can affect fit, form, function, safety, reliability, process capability, or the approved manufacturing process. The answer depends on your customer requirements, internal change control, process similarity, tooling, programming, qualification status, and objective evidence.

Can an aerospace supplier use its own FAIR template instead of the AS9102 forms?

Yes, sometimes, but not by default. A supplier may use its own FAIR template only if customer requirements, contract language, and internal quality procedures allow it, and the template still captures all AS9102-required content in an equivalent, traceable way. If a customer, portal, or flowdown requires the standard forms, then using a custom template is usually not acceptable.

How should suppliers document the rationale for not performing an FAI after a change?

Suppliers should not rely on a brief note or informal judgment when deciding not to perform an FAI after a change. The rationale should be documented as a controlled, traceable risk-based decision that identifies the change, explains why FAI impact was assessed as none, cites objective evidence, and records approvals under the supplier’s quality system and customer requirements.

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