The complete guide to AS9100, NADCAP, FAI, and the quality requirements aerospace primes actually enforce
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The Aerospace Supply Chain Has a Short Memory for Second Chances
You get one bad audit. One missed First Article Inspection. One nonconformance that reaches the flight line. That is all it takes to lose an aerospace contract you spent years building.
Aerospace primes — Boeing, Lockheed Martin, Raytheon, Northrop Grumman — do not operate on goodwill. They operate on documented, auditable evidence that every supplier in their chain meets a defined set of compliance requirements. Those requirements are not flexible. They are not negotiable. And they are layered — meaning AS9100 certification alone does not cover everything your customer may require.
This aerospace supplier compliance standards guide breaks down the full compliance landscape: the standards, the programs, the certification requirements, and what aerospace suppliers actually get audited against on the shop floor.
If you are preparing for your first aerospace contract, adding an aerospace customer to an existing customer base, or trying to understand why your customer’s supplier quality team keeps asking for documentation you did not know you needed — this is where to start.
Before your Stage 1 audit, know exactly where your QMS stands. Run a clause-by-clause gap assessment now — before your registrar does. Download the AS9100 Rev D Gap Assessment Checklist →
In This Guide
- The AS9100 Rev D standard and what it requires beyond ISO 9001
- NADCAP accreditation — what it is, which processes require it, and when it applies
- First Article Inspection (AS9102) — scope, deliverables, and common findings
- Counterfeit parts prevention and AS5553/AS6174
- FOD control requirements
- Customer-specific flow-down requirements and how to manage them
- How to verify a supplier’s certifications before awarding a contract
Table of Contents
👉 Start Here — Top Resources for Aerospace Suppliers
Before you read further, these are the resources aerospace suppliers actually use:
- AS9100 Rev D Standard — ANSI Webstore — The official SAE/AS9100 Rev D standard document. Required reading before certification. Use code CC2026 for 5% off through December 31, 2026.
- AS9100 Training — BSI Group — Lead auditor, internal auditor, and implementation courses for AS9100 Rev D.
- AS9100 Rev D Gap Assessment Checklist — Free 74-item clause-by-clause checklist. Know your gaps before your registrar does.
AS9100 Rev D: The Foundation of Aerospace Quality
AS9100 is the non-negotiable baseline. Every organization supplying parts, assemblies, or services to the aerospace and defense industry — whether you are a Tier 1, Tier 2, or Tier 3 supplier — is expected to hold AS9100 certification or demonstrate that your QMS meets equivalent requirements.
AS9100 Rev D is the current revision, published in 2016. It incorporates all of ISO 9001:2015 verbatim and adds aerospace-specific requirements on top of the quality management foundation. The IAQG — International Aerospace Quality Group — governs the standard and maintains the OASIS certification database.
What AS9100 Adds Beyond ISO 9001
The standard adds requirements that reflect the risk profile of aerospace manufacturing — where a single nonconformance can have catastrophic consequences. Key additions include:
| AS9100 Requirement | ISO 9001 Equivalent | Why It Matters in Aerospace |
|---|---|---|
| Risk management (beyond Clause 6.1) | Risk-based thinking | Formal risk identification, mitigation, and tracking for each program |
| Configuration management | Not required | Ensures part revisions are controlled and traceable across the supply chain |
| First Article Inspection (FAI) | Not required | Required verification that first production part meets all design requirements |
| Product/process change control | Change management | Any deviation from approved baseline requires documented approval |
| Counterfeit parts prevention | Not required | Documented controls to prevent unapproved or fraudulent parts from entering the supply chain |
| FOD prevention | Not required | Foreign Object Damage/Debris programs with documented procedures |
| Customer-designated special requirements | Not required | Flow-down and implementation of prime contractor requirements |
| Key characteristics | Not required | Identification and control of dimensions or features with elevated risk |
Most common finding: Organizations that are ISO 9001 certified assume the gap to AS9100 is small. It is not. The configuration management, FOD, and counterfeit parts requirements alone require building procedures that do not exist in a typical ISO 9001 QMS.
If you are already ISO 9001 certified, the AS9100 vs ISO 9001 comparison breaks down every additional requirement clause by clause.
For complete scope on what AS9100 certification involves, what it costs, and how long it takes, the What Is AS9100? pillar article covers the full picture.
NADCAP: Special Process Accreditation
NADCAP is separate from AS9100 — and your customer will require both.
NADCAP — National Aerospace and Defense Contractors Accreditation Program — is a special process accreditation program managed by the Performance Review Institute (PRI). It applies to organizations performing specific high-risk manufacturing processes where process control is critical to product integrity.
AS9100 certifies your quality management system. NADCAP accredits specific processes within that system. A machined airframe component supplier may need AS9100 certification. If that same supplier performs heat treating, NDT, or chemical processing in-house, NADCAP accreditation is required for those processes — regardless of AS9100 status.
Processes That Require NADCAP Accreditation
| Process Category | Examples |
|---|---|
| Heat Treating | Annealing, aging, stress relief, case hardening |
| Non-Destructive Testing (NDT) | Ultrasonic, radiographic, penetrant, magnetic particle, eddy current |
| Chemical Processing | Anodizing, plating, passivation, conversion coating |
| Welding | Fusion welding per aerospace specifications |
| Coatings | Thermal spray, paint (where specified by prime) |
| Composites | Lay-up, cure, bonding operations |
| Electrical/Electronic Processing | Soldering, conformal coating |
| Fluid Distribution Systems | Tube bending, assembly |
What NADCAP Audits Cover
NADCAP audits are process-specific and technically rigorous. Auditors evaluate process parameters, equipment qualification, operator qualification, traceability of materials, and conformance to applicable customer and industry specifications.
A NADCAP audit is not a QMS audit — it is a process performance audit. Findings are classified as Critical, Major, or Minor. Critical findings result in immediate suspension of work.
If you are a supplier: Do not assume your customer will accept your subcontractor’s NADCAP accreditation for flow-down purposes without reviewing the approved scope. NADCAP accreditation is scope-specific. Heat treating accreditation for aluminum alloys does not cover titanium heat treating.
If your aerospace customer has asked for NADCAP compliance in your supplier requirements — and you are not sure what processes in your facility are in scope — your AS9100 QMS needs a process risk review before your next customer audit. Download the AS9100 Rev D Gap Assessment Checklist →
First Article Inspection: AS9102
First Article Inspection is one of the most frequently cited sources of supplier nonconformances in aerospace.
AS9102 — Aerospace First Article Inspection Requirement — defines the methodology for verifying that the first production article (or first article after a significant change) meets all engineering, design, and manufacturing requirements. The standard is separate from AS9100 but is required by AS9100 Rev D Clause 8.1.3.
What FAI Covers
A complete FAI under AS9102 includes three forms:
| Form | Title | Scope |
|---|---|---|
| Form 1 | Design Documentation | Verification that the correct drawing revision, specifications, and notes are captured |
| Form 2 | Product Accountability | Bill of materials, materials certification, and raw material traceability |
| Form 3 | Characteristic Accountability | Measurement of every dimension and characteristic on the drawing — not a sample |
Form 3 is where most suppliers get tripped up. Every characteristic on the engineering drawing — not a selected subset — must be measured and documented. This includes tolerances, surface finishes, thread forms, and any geometric dimensioning and tolerancing (GD&T) callouts.
When FAI Is Required
FAI is not a one-time event. AS9102 specifies that a new or updated FAI is required when:
- A new part number is introduced to production
- A drawing or specification is revised (full or partial FAI, depending on the scope of change)
- A manufacturing process, facility, or tooling is changed in a way that could affect form, fit, or function
- Production has been inactive for more than two years
Most common finding: Suppliers treat FAI as a drawing check rather than a full measurement event. Partial FAIs submitted without Form 2 material traceability or without measuring all Form 3 characteristics are rejected by customer quality teams and result in production holds.
Counterfeit Parts Standards: AS5553 and AS6174
Counterfeit parts are a documented safety risk in aerospace. The FAA, DoD, and aerospace primes have all implemented mandatory controls. Your QMS must address them explicitly.
Two SAE standards define the requirements:
AS5553 — Fraudulent/Counterfeit Electronic Parts: Avoidance, Detection, Mitigation, and Disposition. Applies to electronic components — integrated circuits, semiconductors, connectors, and any electronics where counterfeit substitution is a risk.
AS6174 — Counterfeit Materiel: Avoidance, Detection, Mitigation, and Disposition. Broader scope covering raw materials, fasteners, and other non-electronic hardware.
What Your QMS Must Include
A compliant counterfeit parts program under AS9100 Rev D requires documented procedures covering:
- Approved supplier lists (ASL): Purchasing only from authorized manufacturers, franchised distributors, or approved aftermarket sources
- Receiving inspection: Risk-based inspection criteria for parts that cannot be sourced from authorized channels
- Traceability: Certificate of conformance, test reports, and chain of custody documentation for all parts
- Suspect/confirmed counterfeit parts: Quarantine, reporting, and disposition procedures — including mandatory reporting to GIDEP (Government-Industry Data Exchange Program) for defense contracts
- Training: Evidence that personnel involved in procurement and receiving inspection are trained to identify suspect parts
If you are a manufacturer and not a distributor, the most critical element is your approved supplier list and purchasing controls — because your customer’s AS9100 audit will verify that you are buying from controlled sources.
FOD Control Requirements
Foreign Object Damage and Debris is a zero-tolerance issue in aerospace.
FOD — Foreign Object Damage or Debris — refers to any substance, material, or item that could potentially damage equipment or endanger personnel. A loose fastener in a fuel system. A rag left in an aircraft cavity. Metal chips in a precision assembly. In aerospace, these are not housekeeping issues — they are quality system failures.
AS9100 Rev D Clause 8.5.1 requires documented controls to prevent FOD throughout manufacturing, assembly, and test operations. Customer-specific FOD requirements are typically more detailed and flow down through purchase order terms.
Minimum FOD Program Elements
✅ Written FOD prevention procedure specific to your facility and processes
✅ Designated FOD critical areas with defined access controls
✅ Tool control program — shadow boards, tool counts, calibrated tool tracking
✅ Contamination controls during assembly and inspection operations
✅ FOD walks and documented area inspections on defined frequency
✅ Employee training and awareness records
✅ FOD incident reporting and corrective action process
✅ Customer notification procedure when FOD is suspected or confirmed
Most common finding: FOD programs exist as a procedure document but are not operationally active. Auditors look for evidence — completed FOD walk records, tool control logs, training records — not just a written procedure. The procedure without the records is a Major finding.
Customer Flow-Down Requirements
Your prime contractor’s requirements are your requirements.
This is the element that surprises suppliers who are new to aerospace. AS9100 certification means you have a compliant quality management system. It does not mean your prime contractor’s specific engineering, quality, and documentation requirements are automatically met. Those flow down — meaning they are passed from the prime to you through purchase order terms, quality clauses, and source control documentation.
Common Flow-Down Requirements
| Category | Examples |
|---|---|
| Quality plan | First Article requirements, inspection frequencies, statistical process control |
| Engineering | Specification compliance, drawing revision control, DER approvals |
| Material | Material certifications, approved material sources, trace requirements |
| Manufacturing | Approved process specifications (e.g. BAC, SPE, DPS), NADCAP process approvals |
| Documentation | Record retention requirements (typically 10+ years for flight-critical parts) |
| Access and oversight | Right-to-access for customer source inspection, government source inspection |
| Reporting | GIDEP reporting, escape reporting, timelines for nonconformance notification |
Managing Flow-Down in Your QMS
Your QMS must have a documented process for:
- Reviewing purchase orders for quality clauses before accepting the order
- Translating customer requirements into internal work instructions and inspection plans
- Verifying that sub-tier suppliers (your suppliers) receive applicable flow-down requirements
- Maintaining records that demonstrate compliance with customer-specific requirements
If you are receiving flow-down requirements you do not understand: Your customer’s supplier quality team is your first contact. Do not guess. Documenting a misunderstood requirement incorrectly is worse than asking for clarification — because the audit finding will be a major nonconformance, not a simple misunderstanding.
If you are evaluating whether your quality system is ready for AS9100 certification, start with the How Much Does AS9100 Certification Cost? article for a complete breakdown of what certification actually involves.
BSI Group offers AS9100 training specifically designed for suppliers building compliant QMS documentation — covering the clause requirements and flow-down obligations that come with aerospace contracts.
How to Verify Supplier Certifications
Never take a supplier’s word for AS9100 certification. Verify it directly.
The IAQG OASIS Database is the official global registry for AS9100, AS9110, and AS9120 certifications. Every accredited certification is listed with scope, effective date, expiration date, and the certification body that issued it. If a supplier claims AS9100 certification and they are not in OASIS, the certification is not valid.
What to Verify in OASIS
- Certification status: Active, suspended, or withdrawn
- Scope of certification: Does it cover the specific product category or process your supplier is performing?
- Expiration date: AS9100 certificates expire and require surveillance audits — a certificate that has not been renewed is not valid
- Certification body: Is the CB accredited by a recognized accreditation body (ANAB, DAkkS, UKAS)?
For NADCAP accreditation verification, the PRI supplier database at pri-network.org lists all accredited suppliers by commodity and scope.
If you are a quality manager building or updating an approved supplier list for an aerospace program — your supplier evaluation process needs to include OASIS verification as a mandatory step before award and at each annual review.
Compliance Checklist for Aerospace Suppliers
Use this checklist to assess your current compliance posture before a customer audit or certification audit.
Quality Management System
✅ AS9100 Rev D certification current and active in OASIS
✅ QMS manual and procedures documented and controlled
✅ Internal audit program covers all AS9100 clauses — not just ISO 9001 requirements
✅ Management review records demonstrate review of aerospace-specific metrics
First Article Inspection
✅ FAI procedure documented per AS9102
✅ Form 1, Form 2, and Form 3 completed for all active part numbers
✅ FAI triggers defined — changes that require new or partial FAI
✅ FAI records retained and retrievable
Counterfeit Parts
✅ Counterfeit parts prevention procedure in place
✅ Approved supplier list (ASL) current and controls defined
✅ Receiving inspection criteria address suspect parts
✅ Personnel training records current
FOD
✅ FOD prevention procedure active and specific to your facility
✅ FOD walk and inspection records maintained on required frequency
✅ Tool control program in place with records
✅ Employee training documented
Flow-Down
✅ Purchase order review process in place
✅ Customer quality clauses translated to internal requirements
✅ Sub-tier flow-down process documented and verified
✅ Record retention meets customer requirements (typically 10+ years)
NADCAP (if applicable)
✅ All in-scope special processes identified
✅ NADCAP accreditation current for each process
✅ Scope of accreditation matches actual work performed
✅ Sub-tier NADCAP requirements verified and documented
FAQ
What is the difference between AS9100 and NADCAP?
AS9100 Rev D is a quality management system standard that certifies your organization’s overall quality processes — planning, documentation, corrective action, customer satisfaction, and so on. NADCAP is a special process accreditation that applies to specific manufacturing processes such as heat treating, NDT, chemical processing, and welding. AS9100 certification is a QMS-level requirement. NADCAP is a process-level requirement. Aerospace suppliers performing special processes are typically required to hold both.
Do I need AS9100 certification to supply aerospace parts?
In most cases, yes — if you are a direct supplier (Tier 1 or Tier 2) to an aerospace prime or defense contractor. Some lower-tier commodity suppliers may not be required to hold AS9100 certification, but customer flow-down requirements and purchase order quality clauses will define the specific requirement. Review your customer’s supplier quality requirements before assuming certification is not needed.
How do I know if my process requires NADCAP accreditation?
Review your customer’s purchase order quality clauses and their approved supplier requirements document. Primes typically maintain a list of processes that require NADCAP accreditation for their programs. If you perform heat treating, NDT, chemical processing, or welding on aerospace parts and your customer has not specified NADCAP — ask. The absence of a requirement on the PO does not always mean the requirement does not exist.
What is a First Article Inspection and when is it required?
A First Article Inspection (FAI) is a formal verification process, defined by AS9102, that the first production article meets all design and engineering requirements. It is required for new part introductions, after drawing or specification revisions, after significant manufacturing process or tooling changes, and after production gaps of two or more years. A complete FAI requires documentation on three forms covering design documents, material traceability, and measurement of every drawing characteristic.
How long does AS9100 certification take?
For an organization with no existing quality management system, the implementation and certification process typically takes 9 to 18 months. Organizations already certified to ISO 9001 can typically close the gap to AS9100 in 6 to 12 months, depending on the number of additional requirements that need to be built out. The How Much Does AS9100 Certification Cost? article covers timelines and costs in detail.
What is the OASIS database and how do I use it?
OASIS — Online Aerospace Supplier Information System — is the IAQG-maintained database of all AS9100, AS9110, and AS9120 certifications worldwide. You can search by organization name, location, or CAGE code to verify a supplier’s certification status, scope, expiration date, and issuing certification body. Access it at oasis.sae.org. Verifying supplier certifications in OASIS should be a standard step in your approved supplier list maintenance process.
What are customer flow-down requirements in aerospace?
Flow-down requirements are the specific quality, engineering, documentation, and process requirements that a prime contractor passes down to their supply chain through purchase order terms and quality clauses. They are legally binding once accepted on a PO. Common examples include FAI requirements, material certification requirements, NADCAP requirements for special processes, record retention periods, and customer source inspection rights. Your QMS must have a documented process for reviewing, implementing, and flowing these requirements to your own sub-tier suppliers.
Can I use my ISO 9001 certification for aerospace customers temporarily while pursuing AS9100?
In most cases, no. ISO 9001 certification does not meet AS9100 requirements. Some customers may grant a temporary waiver for lower-risk commodity suppliers, but for any direct aerospace supply involving flight-critical parts or assemblies, AS9100 certification is typically required before production can begin. Discuss your timeline with your customer’s supplier quality team — do not assume a waiver will be granted.
📥 Free Resources
AS9100 Rev D Gap Assessment Checklist — 74-item clause-by-clause checklist for aerospace suppliers assessing their QMS before certification. Covers every AS9100-specific requirement beyond ISO 9001.
ISO 9001 Roadmap — Step-by-step implementation guide for manufacturers building or improving a quality management system. Useful as a foundation before layering AS9100 requirements.
Manufacturing Compliance Checklist — Practical compliance reference covering key ISO, OSHA, and quality requirements for production environments.
Supplier Quality Checklist — Evaluation tool for assessing supplier quality controls and flow-down compliance before audits or new contracts.
ISO 13485 Gap Assessment Checklist — Free checklist for medical device manufacturers assessing their QMS against ISO 13485 requirements.
Not Sure What to Do Next?
🔹 If you are new to aerospace and need to understand AS9100 from the ground up — start with What Is AS9100? for a complete overview of the standard, certification process, and supply chain requirements.
🔹 If you are ready to buy the AS9100 Rev D standard — purchase the official document through the ANSI Webstore. Use code CC2026 for 5% off through December 31, 2026. The standard is available in digital and print formats and ships internationally.
🔹 If you need AS9100 training for your team or are selecting a certification body — BSI Group offers the full range of AS9100 courses from awareness through lead auditor, and serves as both a training provider and accredited certification body.
Aerospace compliance is not a project with a finish line. Certification is the beginning. The organizations that hold their approvals and grow within the supply chain are the ones that build compliance into operations — not just into audit prep.
The Standards Navigator covers the full aerospace compliance landscape, from AS9100 certification requirements to NADCAP process accreditation and FAI methodology. Use the resources above to make your next audit a confirmation of what you already know — not a discovery of what you missed.
Stay Ahead of Aerospace Compliance Changes
Losing an aerospace approval because a standard revision or customer requirement changed while you were focused on production is the most preventable kind of failure. Most organizations that fall behind on compliance don’t miss the requirement — they miss the update.
The suppliers who keep their approvals long-term are the ones who treat compliance information the same way they treat production scheduling: as an ongoing operational discipline, not a one-time project.
The Standards Navigator covers AS9100, NADCAP, FAI, and the full aerospace supplier compliance landscape — explained in plain language for quality managers and operations teams who need to act on the information, not just read it.
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