When a new MIM tool is first run, the parts must undergo a formal qualification process before production begins. This process goes by different names depending on the industry: FAI (First Article Inspection) for general and aerospace, PPAP (Production Part Approval Process) for automotive.
MIM FAI (First Article Inspection) — what is included:| FAI Element | Description | Commercial Standard | Automotive Standard |
|---|---|---|---|
| Dimensional report | All dimensions per drawing measured and reported | Critical dimensions only | 100% of all dimensions |
| Material test report | Chemistry + mechanical properties | CoA from material supplier | In-house test from witness coupons |
| Process capability | CpK study on critical dimensions | Not always required | CpK ≥ 1.33 required |
| Gauge R&R | Measurement system analysis | Optional | Required for all gauges |
| Process flow | Documented manufacturing steps | Simple list | Full process flow diagram |
| PFMEA | Risk assessment | Optional | Required |
| Control plan | Inspection and control methods | Basic plan | Detailed per AIAG format |
For automotive MIM suppliers, PPAP per AIAG guidelines requires Level 3 submission including all 18 elements: design records, PFMEA, process flow, control plan, MSA, dimensional results, material/performance test results, initial process capability study, and sample parts. This is significantly more documentation than commercial FAI.
Quick Q: What is MIM First Article Inspection (FAI)?FAI is the formal qualification process for a new MIM tool or process change. It includes full dimensional measurement of the first production parts, material testing (chemistry, mechanical properties, density), and process capability analysis (CpK). For automotive applications, this expands to a full PPAP Level 3 submission with 18 documented elements per AIAG guidelines.
The FAI is the single most important quality milestone in any MIM program — it is where the mold design, shrinkage compensation, and process parameters are validated before production begins.