First Article Inspection for Every PCB Assembly – 100% Verified, AS9102-Ready

Every First Piece, Fully Verified

Highleap performs 100% First Article Inspection (FAI) on every new PCB assembly project before volume production. Our inspection process ensures the first piece inspection report aligns fully with your design intent, component specifications, process parameters, and test requirements.

From AS9102 first article inspection documentation to functional test validation, we provide traceable, structured, and customer-approved inspection before mass release.

FAI Is Embedded in Every Initial Production Inspection

First article PCBs at Highleap are not lab samples — they are fully built production units using your real BOM, actual stencil, exact pick-and-place programming, and reflow profile. The initial production inspection becomes your quality benchmark.

Every first article inspection process includes:

✅ Component placement verification – Orientation, polarity, footprint match

✅ Solder joint analysis – AOI, X-ray, or visual inspection based on IPC standards

✅ Measured electrical values – Voltage, resistance, current at test points

✅ Performance testing – Interface logic, power-up behavior, signal response

✅ Documentation review – BOM, Gerber, silkscreen, test plan alignment

✅ PCB design validation – Checks between design intent and build result

✅ Material compliance verification – Right part, right spec, right lot

All findings are consolidated in a structured FAI report, optionally formatted to AS9102 standard.

FAI Triggers and Scenarios We Handle

Our first piece inspection process is mandatory in the following cases:

• New customer or new product
• Modified BOM or PCB layout
• Switch in factory line, SMT profile, or reflow setting
• Substitution of materials or critical components
• Design transfer between facilities or vendors
• Return to production after hold, deviation, or complaint
• AS9102 or industry-mandated quality control

We help you establish a production-ready baseline that meets both engineering and regulatory expectations.

What You Get in a Highleap First Article Inspection Package

✅ A documented first piece inspection report, tied to board serial ID

✅ Clear pass/fail status by requirement, per board or per function

✅ Images of component placement, solder joints, and X-ray/AOI results

✅ Test logs and functional performance data (if testing is in scope)

✅ Engineering comments on observed build issues or DFM risks

✅ FAI report in standard or AS9102-compliant format

✅ Digital archiving for traceability, audit, and future batches

Every PCBA is compared against your expectations. Every deviation is explained, corrected, and revalidated.

Required Files and Inputs for Your First Piece Inspection

To run an accurate and efficient FAI, please share:

• Final Gerber, BOM, centroid, and stack-up
• Functional test script or golden unit
• Acceptance standards (IPC class, test tolerances, AS9102 format if needed)
• Special instructions for critical components, mechanical interfaces, or signal paths
• Notes for any compliance verification criteria tied to your application (e.g. MIL-STD, automotive, telecom)

If you don’t have a defined PCB assembly inspection checklist, we can help you create one.

Why Engineers Trust Our FAI Capabilities

• Every project includes initial production inspection as a standard procedure
• Quality team trained in IPC, ISO, and AS9102 protocols
• Tight control across the full workflow — from data package to pick-and-place to test execution
• Proven track record in medical, aerospace, robotics, and telecom applications
• Seamless integration of FAI, AOI, functional testing, and full documentation
• Clear, responsive communication with actionable engineering feedback — not boilerplate reports