Quality at A3D is more than a part getting accepted. It is a controlled, repeatable process from quote through the life of the part — sometimes years after it ships. Visual inspection is already in that process. The paid inspection levels exist because a heatmap, an AS9102 first-article packet, a Z1.4 lot sample, and a CPK study are different kinds of proof.
If you order parts, someone is already looking at them. Standard inspection is visual, as product moves through the shop. On MJF, that happens at unpack and through any post-processing. The people doing that work are trained to catch nonconforming features as they go.
Anything past standard inspection is an add-on. Pick the level that matches the question you actually need answered.
T1 — Part vs CAD (3D Comparison)
Part vs CAD is a precision scan compared directly to the 3D CAD model. We scan one part and compare it to the CAD. The heatmap shows how far each area is from nominal: how “out” that section is.
- Process: Scan the as-built geometry. Compare that captured model to the expected design.
- Outcome: A heatmap report with a visual and quantitative read of conformity — where the part matches the model, and where it doesn’t.
- What drives the quote: Number of scans for the part.
Use T1 when you need qualitative and quantitative proof the whole shape matches the model.
What a First Article Actually Is
A first-article inspection report (FAIR, FAI, first article — same idea) is a method to document and prove a product meets every requirement on the drawing and in the process.
In traditional manufacturing, you make a complete first piece, record the process and the measurements, and if that piece is in tolerance you release the rest of the run. Sampling after that is how you keep the lot honest.
In additive we build in batches, so “first piece off the machine” doesn’t mean the same thing. The FAIR still locks the configuration, the materials and post-process, and the dimensions. It is the benchmark for what “good” looks like on that job, not a trophy for part number one.
T2 — First Article (AS9102 FAIR)
First Article is an in-depth inspection of the produced part against all design specifications, reported IAW AS9102.
- Process: A thorough examination so every detail of the drawing is accounted for. Form 1 is configuration management. Form 2 is materials and post-processes. Form 3 is the dimensional requirements of the drawing.
- Outcome: An AS9102 First Article Inspection Report that validates the part against design specifications and sets the quality benchmark for the job.
- What drives the quote: Number of dimensions on the print, and number of scans for the part.
Use T2 when you need to know whether 3D printing can hit the drawing, or you need to freeze the configuration.
T3 — Lot Sampling (Z1.4)
Lot Sampling is a statistical sampling plan on a production lot. The design is done. Now you need the delivered product to stay in conformance.
- Process: Sample size comes from lot size, inspection level, and acceptable quality level (AQL), following ANSI/ASQ Z1.4. Critical-to-quality features are measured on that sample so you can see the range of deviation from nominal.
- Outcome: A report with dimensional measurements of the inspected parts, and statistical confidence the batch is consistent.
- What drives the quote: Lot size, inspection level, and AQL.
Use T3 for production quantity, not for a one-part scan.
T4 — Process Capability (CPK)
Process Capability is an analytical look at whether the manufacturing method is in control on selected features over a real sample set — not whether one part passed. This is how you test if additive can hold an existing drawing across a lot. Automotive programs ask for this often.
- Process: Measure up to five critical-to-quality (CTQ) features on 30 or more parts. More than five CTQs is a custom quote.
- Outcome: A CPK process-capability report: which dimensions are controlled, and where the process needs work.
- What drives the quote: Lot size and part complexity, plus that five-CTQ cap.
Don’t pick T4 for a handful of prototypes.
When a Part Doesn’t Meet the Print
If a feature is off the drawing, that’s a nonconformance. The useful version is catching it here, during inspection, so the part can be remade or reviewed with you before it ships. Sometimes you approve a written deviation and the part still goes. The version nobody wants is a part that ships and you find the problem. Inspection exists so that last case stays rare. This article does not walk through A3D’s internal disposition process; that stays on the quote and the quality system, not on a prospect page.
You can add a paid level on top of the visual check. You don’t skip the visual pass because you bought a FAIR.
On the RFQ, name the inspection level, the four dimensions or the five critical ones, the print, and the quantity.
We Take Quality & Compliance Seriously
A3D is ISO 9001:2015 and AS9100:2016 registered and ITAR registered. These certifications cover A3D’s additive manufacturing, assembly, finishing, and supplier sourcing activities. Parts created by our supplier network route through our Phoenix headquarters for final QA before shipment, and supplier qualification is governed by our QMS.
Ready to Spec Inspection on a Quote?
Contact us: www.a3dmfg.com/contact-us
Phone: 480.454.5037
Email: [email protected]
