Form 3

Form 3 is the AS9102 First Article Inspection (FAI) form used in the aerospace and defense industry to record detailed inspection results for each specified characteristic of a part or assembly. It is one of the three standardized forms defined in AS9102 and focuses on the dimensional, material, and other measurable characteristics that verify a part meets design requirements.

What Form 3 includes

Form 3 typically captures, for each ballooned or otherwise identified characteristic:

• Characteristic or balloon number, matching the engineering drawing or model
• Description of the characteristic (for example, a specific dimension, feature, or material property)
• Design requirement or nominal value, including tolerance
• Actual measurement results or test values
• Acceptance status (pass / fail) for each characteristic
• Inspection method, equipment, or gage used, when required
• References to any associated nonconformances, deviations, or concessions

In operation, Form 3 links directly to Form 1 (part-level summary and configuration) and Form 2 (material and process details). Together, the three forms provide evidence that the first production run of a part has been inspected against all design characteristics and that results are documented in a consistent structure.

How Form 3 shows up in manufacturing systems

In modern aerospace and other regulated manufacturing environments, Form 3 is often managed in digital systems such as MES, QMS, or specialized FAI software. These systems commonly:

• Import or reference ballooned drawings or 3D models to auto-generate characteristic lines
• Enforce mandatory fields for characteristics, requirements, and results
• Link each characteristic to work orders, operations, or inspection plans
• Capture electronic measurement data from gages, CMMs, or test equipment
• Provide traceability from Form 3 entries to nonconformance records, CAPAs, or MRB decisions

Software can support consistent completion of Form 3 and help maintain traceability, but correct use, configuration, and change control are still required to align with AS9102 expectations.

Common confusion

• Form 3 vs Form 1 and Form 2: Form 1 summarizes the part and FAI, Form 2 focuses on materials and special processes, and Form 3 contains the detailed characteristic results. All three are part of a complete AS9102 FAI package.
• Form 3 vs general inspection reports: Many manufacturers use generic inspection reports or certificates of conformance. Form 3 is specific to AS9102 FAI and is structured to cover every defined design characteristic for the first article, not only sample checks or key characteristics.

Link to the AS9102 Rev C context

Under AS9102 Rev C, Form 3 is used to demonstrate that each design characteristic has been inspected on the first article and that results are recorded in a consistent, traceable way. Digital implementations frequently tie Form 3 lines to drawing balloon numbers, bills of materials, operations, and nonconformance records to support audit readiness and ongoing production validation.