First Article Testing for Defence Contracts

Understanding First Article Testing in Defence Manufacturing

First Article Testing (FAT) represents one of the most critical quality assurance processes in defence manufacturing, serving as the definitive verification that a contractor can produce parts and assemblies that meet all design specifications, engineering requirements, and contractual obligations. For defence contractors across Atlantic Canada and throughout the Canadian defence industrial base, mastering FAT requirements is essential for securing and maintaining contracts with the Department of National Defence (DND), the Canadian Armed Forces, and allied nations under programmes such as the North Atlantic Treaty Organization (NATO) and the United States Department of Defense.

The rigorous nature of first article testing stems from the fundamental principle that defence equipment must perform flawlessly in life-or-death situations. Whether manufacturing components for the Halifax-class frigates maintained at Irving Shipbuilding, producing precision parts for Light Armoured Vehicles, or fabricating assemblies for aerospace applications, Maritime manufacturers must demonstrate an unwavering commitment to quality that begins with comprehensive first article inspection and testing.

The Regulatory Framework Governing First Article Testing

Defence contractors in Canada operate within a complex regulatory environment that draws upon both domestic and international standards. Understanding these requirements is fundamental to successful FAT implementation and contract compliance.

Canadian Defence Standards and Specifications

The Department of National Defence utilises a hierarchical system of specifications and standards that govern first article testing requirements. The primary Canadian standard, D-02-006-008/SG-001, establishes the quality assurance programme requirements for defence contracts, including specific provisions for first article inspection. This standard aligns with NATO AQAP (Allied Quality Assurance Publications) requirements, ensuring interoperability with allied nations' defence procurement systems.

Key Canadian defence quality standards include:

• CFTO C-02-005-001/AM-001 – General Specification for Quality Assurance

• D-02-006-013/SG-001 – First Article Inspection Requirements

• ISO 9001:2015 with AS9100D aerospace supplement where applicable

• ITAR (International Traffic in Arms Regulations) compliance for US-origin technical data

• Controlled Goods Programme registration and compliance requirements

AS9102 First Article Inspection Requirements

For aerospace and many precision defence applications, AS9102 Revision B serves as the definitive standard for first article inspection documentation. This standard, published by the International Aerospace Quality Group (IAQG), establishes a uniform approach to FAI that is recognised globally. The standard requires three primary forms:

• Form 1 – Part Number Accountability: Documents the complete part configuration including design requirements, drawing numbers, and revision levels

• Form 2 – Product Accountability: Records raw material certifications, special processes, and functional testing results

• Form 3 – Characteristic Accountability: Captures actual measured values for all design characteristics against specified tolerances

The standard mandates that 100% of design characteristics be verified during first article inspection, with actual measured values recorded for dimensional features. This comprehensive approach ensures that manufacturing processes are capable of consistently producing conforming products.

Planning and Preparation for First Article Testing

Successful first article testing begins long before the first measurement is taken. Thorough preparation significantly reduces the risk of costly failures and programme delays that can damage a contractor's reputation and financial position.

Contract Review and Requirements Analysis

The initial phase of FAT preparation involves comprehensive contract review to identify all applicable testing requirements. Defence contracts typically specify first article testing through various mechanisms:

• Direct contractual clauses requiring FAT completion before production authorisation

• Referenced specifications and standards incorporated by the Statement of Work

• Technical Data Package requirements specifying inspection and testing methods

• Customer-specific quality provisions beyond standard requirements

• Lot acceptance testing requirements that follow successful FAT completion

For Nova Scotia defence contractors working with the Royal Canadian Navy or supporting shipbuilding programmes, contract requirements often include specific provisions for marine environmental testing, corrosion resistance verification, and compatibility with existing ship systems.

Manufacturing Process Qualification

Before commencing first article production, contractors must ensure all manufacturing processes are qualified and documented. This includes:

• Special Process Certifications: Heat treatment, welding, plating, painting, and non-destructive testing processes must be performed by certified operators using approved procedures

• Equipment Calibration: All measurement and test equipment must have current calibration certificates traceable to national standards (typically the National Research Council of Canada)

• Material Certifications: Raw materials must be accompanied by certified mill test reports or certificates of conformance

• Tooling Qualification: Production tooling must be verified for dimensional accuracy and capability

Executing First Article Inspection and Testing

The execution phase of first article testing requires meticulous attention to detail and comprehensive documentation. The inspection and testing process must verify every design characteristic while generating objective evidence of conformance.

Dimensional Inspection Procedures

Dimensional verification forms the foundation of most first article inspections. Modern defence manufacturing increasingly relies on advanced metrology equipment to achieve the precision required by contemporary weapon systems and platforms:

• Coordinate Measuring Machines (CMMs): Programmable measurement systems capable of verifying complex geometries to tolerances of ±0.001 mm or better

• Optical Comparators: Profile inspection of complex contours and small features

• Surface Roughness Testers: Verification of surface finish requirements critical for fatigue life and sealing surfaces

• Gauge Blocks and Precision Standards: Reference standards for calibration verification

• Laser Scanning Systems: Rapid capture of complex surface geometries for comparison against CAD models

For Maritime defence contractors, environmental conditions during measurement must be carefully controlled. The Atlantic Canada climate, with its significant humidity variations and temperature fluctuations, can affect measurement accuracy. Temperature-controlled inspection areas maintained at 20°C ±2°C with humidity below 60% RH are essential for precision measurement work.

Material and Process Verification

Beyond dimensional inspection, first article testing must verify material properties and process conformance:

• Chemical Analysis: Verification that material composition meets specification requirements

• Mechanical Testing: Tensile strength, yield strength, elongation, and hardness testing per applicable standards

• Non-Destructive Testing: Radiographic, ultrasonic, magnetic particle, and liquid penetrant inspection for internal and surface defects

• Corrosion Resistance Testing: Salt spray testing per ASTM B117 or equivalent standards, particularly critical for naval applications

• Coating Thickness Measurement: Verification of protective coating thickness using magnetic or eddy current methods

Functional and Performance Testing

Many defence components require functional testing to verify performance under operational conditions. First article testing protocols may include:

• Proof and Burst Pressure Testing: Hydraulic and pneumatic components tested to 150% and 300% of working pressure respectively

• Environmental Testing: Exposure to temperature extremes, humidity, vibration, and shock per MIL-STD-810 or equivalent

• Electrical Testing: Continuity, insulation resistance, and dielectric withstand testing for electrical assemblies

• Fit and Function Verification: Assembly of components into higher-level assemblies to verify interface compatibility

Documentation and Reporting Requirements

The documentation generated during first article testing serves as the permanent record of conformance and forms the basis for production authorisation. Defence contracts typically require specific documentation formats and retention periods.

First Article Test Reports

A comprehensive First Article Test Report (FATR) must include:

• Complete identification of the tested article including part number, revision, serial number, and lot number

• Reference to all applicable drawings, specifications, and contract requirements

• Actual measured values for all characteristics with comparison to specified tolerances

• Material certifications and test reports for raw materials

• Special process certifications including operator qualifications and procedure references

• Non-destructive testing reports with interpretation by certified Level II or III inspectors

• Photographs documenting condition and identification markings

• Statement of conformance or detailed nonconformance reports for any discrepancies

Handling Nonconformances

When first article inspection reveals characteristics outside specified tolerances, contractors must follow established nonconformance procedures. Options typically include:

• Rework: Bringing the characteristic into conformance through additional manufacturing operations

• Use-As-Is Disposition: Engineering evaluation determining the nonconformance does not affect form, fit, or function (requires customer approval for defence contracts)

• Scrap and Refabrication: Rejection of the nonconforming article and production of a replacement

Canadian defence contracts typically require formal submission of Engineering Disposition Requests (EDRs) for any proposed use-as-is or repair dispositions, with approval authority retained by the Design Activity or their designated representative.

Special Considerations for Maritime Defence Contractors

Defence contractors operating in Atlantic Canada face unique challenges and opportunities related to the region's significant naval presence and maritime industry heritage.

Naval Equipment Requirements

Components destined for Royal Canadian Navy vessels must meet stringent requirements for the marine environment:

• MIL-STD-167-1A vibration requirements for shipboard equipment

• MIL-S-901D shock resistance for Grade A and Grade B equipment

• Corrosion Protection: Enhanced requirements for salt spray resistance, typically 500-1000 hours minimum

• Electromagnetic Compatibility: MIL-STD-461 requirements for electromagnetic interference control

Supply Chain Considerations

Nova Scotia's geographic position presents both challenges and advantages for defence supply chains. While proximity to major naval bases at CFB Halifax provides logistical advantages, contractors must carefully manage:

• Lead times for specialty materials and components from central Canadian or international suppliers

• Access to certified special process facilities for heat treatment, plating, and non-destructive testing

• Coordination with prime contractors for witness inspections and customer source inspection requirements

Achieving First-Time Success in First Article Testing

Experienced defence contractors recognise that first article testing success depends on proactive quality management throughout the manufacturing process, not merely inspection at completion.

Best Practices for FAT Success

• Early Engagement: Begin FAT planning during contract review and proposal development

• Characteristic Classification: Identify critical, major, and minor characteristics to focus inspection resources appropriately

• In-Process Verification: Implement inspection holds at key manufacturing stages to catch problems early

• Dimensional Studies: Conduct capability studies on critical characteristics to verify process capability before first article production

• Documentation Review: Perform thorough review of all documentation before formal submission

• Lessons Learned: Maintain databases of previous FAT experiences to prevent recurrence of problems

Common Causes of First Article Rejection

Analysis of first article failures across the defence industry reveals common root causes:

• Incomplete or incorrect interpretation of drawing requirements

• Inadequate process capability for tight-tolerance features

• Missing or expired certifications for special processes

• Documentation errors including incorrect revision levels or missing data

• Failure to verify all characteristics, particularly notes and general tolerances

Partner with Experienced Defence Engineering Professionals

First article testing represents a critical gateway in defence manufacturing that demands expertise, precision, and unwavering attention to detail. The consequences of FAT failure extend beyond immediate programme delays to include potential damage to contractor reputation and future business opportunities with defence customers.

Sangster Engineering Ltd., based in Amherst, Nova Scotia, provides comprehensive engineering support to defence contractors throughout Atlantic Canada and beyond. Our team understands the unique requirements of Canadian defence procurement and the specific challenges facing Maritime manufacturers. From initial contract review and FAT planning through inspection execution and documentation preparation, we deliver the technical expertise needed to achieve first-time success in first article testing.

Whether you're pursuing your first defence contract or seeking to improve your FAT processes for existing programmes, contact Sangster Engineering Ltd. to discuss how our professional engineering services can support your defence manufacturing objectives. Our commitment to quality and technical excellence aligns perfectly with the demanding standards of the Canadian defence industry.

Partner with Sangster Engineering

At Sangster Engineering Ltd. in Amherst, Nova Scotia, we bring decades of engineering experience to every project. Serving clients across Atlantic Canada and beyond.

Contact us today to discuss your engineering needs.