INITIAL SAMPLE INSPECTION REPORT (ISIR)
A first article inspection report (FAIR) confirms, prior to the start of series production, that a product meets all agreed inspection criteria. Microvista provides the metrological evidence for this using industrial computed tomography: non-destructive, VDA- and PPAP-compliant, with an initial assessment within one working day and express testing in under three days.
How does industrial CT ensure compliance with VDA Volume 2 and PPAP during initial sampling?
Microvista supports the creation of initial sample inspection reports using CT-based inspection results: dimensional measurements, standardised porosity analyses and joint inspections from a single scan, with documented measurement uncertainty, formatted according to your specifications for sampling in accordance with VDA Volume 2 or PPAP.
The reason for using CT: the first-article inspection report must provide evidence for every agreed inspection characteristic, including those inside the component. This is precisely where conventional measurement techniques reach their limits, as porosity, wall thickness variations and joint locations cannot be assessed by tactile or optical means without destroying the first-article sample.
Industrial CT extends conformity assessment to the entire volume of the component, in a non-destructive and reproducible manner.
Why the First Article Inspection Report (FAIR) determines whether a product is approved for mass production
An initial sample test report documents the test results for the first parts produced in the manufacturing process. The EMPB serves as evidence that a supplier has understood the product requirements and is able to ensure product quality under real production conditions; the product only enters series production once it has been approved by the customer.
The significance of the EMPB in the automotive industry stems from IATF 16949 [3]: OEMs make initial sampling a mandatory requirement in quality management, as proof that the parts meet the agreed quality standards. An incomplete report prevents approval and thus the start of series production.
First-article inspection report in accordance with VDA and PPAP: Who is responsible for providing which evidence?
Two standards govern which supporting documents should be included in the report and who is responsible for providing them: VDA Volume 2 in Europe and PPAP in North America.
VDA Volume 2 (PPF procedure): This standard, published by the German Association of the Automotive Industry, governs production process and product approval in Europe [1]. The template level is agreed between the customer and the supplier; it defines the scope of the initial sample inspection report. Specifically, for an initial sample inspection report in accordance with VDA, this means:
MICROVISTA
delivers the metrological evidence
- Dimensional sheets and measurement records from the CT volume model
- Pore report to P202/P203 or OEM standard
- Wall thickness and joint analyses
- CAD actual/nominal comparison as false-colour rendering
- Measurement uncertainty and reference objects documented
SUPPLIER (YOU)
creates and owns the ISIR
- Cover sheet with master data
- FMEA and control plan
- Process evidence from production under series conditions
- Signature and submission to the customer
MATERIAL SUPPLIER
delivers the material evidence
- Material certificates for the material used
- e.g. inspection certificate 3.1 to EN 10204
PPAP (Production Part Approval Process): The North American equivalent of the AIAG operates with five submission levels [2]; Level 3, with a full report, is standard. PPAP and PPF differ in their level of detail, but require the same metrological evidence: Microvista provides the test results for both procedures; we tailor the report format to your specifications so that you can incorporate measurement reports and findings directly into your sampling documentation.
In a nutshell: the metrological evidence comes from Microvista, the organisational evidence from the supplier, and the material certificates from the materials supplier.
CT measurement technology for first-article inspection: scanning, 3D model, analysis
For sampling, we produce a high-resolution CT scan: the initial sample rotates between the X-ray source and the detector; a complete 3D volume model is reconstructed from several thousand X-ray images, covering both the interior and exterior, with a spatial resolution of 0.02 to 1 mm depending on the component size. Our metrology engineers carry out the analyses required by your quality assurance test plan on this volume model. In a nutshell: the metrological evidence comes from Microvista, the organisational aspects from the supplier, and the material certificates from the materials supplier.
Dimensional inspection and CAD target-actual comparison
Once the surface has been defined, we measure all design features directly in the solid model, including undercuts, internal channels and free-form surfaces. The comparison with your CAD data is documented as a false-colour representation and confirms compliance with the tolerances. Measurement accuracy starts at 0.02 mm, depending on the component size and material.
Porosity analysis in accordance with the standard (P202, P203)
We assess pores, cavities and inclusions in accordance with P202, P203 or manufacturer’s standards (such as VW 50093, ZFN 1136), including the selection of the inspection area in accordance with the relevant standards and the determination of areas and equivalent circles. For castings made of aluminium, magnesium and iron, this is the most common reason why initial sampling requires CT data.
Wall thickness, joint and assembly inspection
We measure the wall thickness distribution across the entire component, not just at random sample points; this is particularly important for thin-walled components such as electric motor housings. We inspect welds, solder joints and adhesive bonds for porosity and bonding defects, for example on hairpin stators; we have analysed more than 100,000 hairpin welds. We assess assembled sub-assemblies without dismantling them.
For easily accessible individual dimensions with tight tolerances, tactile measurement technology may be more accurate or cost-effective. The advantage of CT is that it allows many external and internal features to be assessed from the same data set whilst leaving the initial prototype intact: it remains available for functional testing or presentation to the customer, and the early use of CT helps to identify defects at an early stage before they delay the start of series production.
Overview: From inspection criterion to evidence in the EMPB
The table shows which CT evaluation covers which inspection characteristic and what evidence this provides for your sampling records.
| Characteristic | CT evaluation at Microvista | Evidence in the inspection report |
|---|---|---|
| Dimensions and geometry | Dimensional evaluation in the volume model, CAD actual/nominal comparison | Measurement record per drawing characteristic, false-colour rendering |
| Porosity | Analysis to P202/P203 or OEM standard (VW 50093, ZFN 1136) | Pore report with size, position and assessment |
| Wall thickness | Full-surface wall thickness analysis of the entire part | Wall thickness report with tolerance assessment |
| Joints | Inspection of welds, soldered and adhesive joints | Findings on pores and bonding defects |
| Assembly state | Assembly inspection without disassembly | Documentation of fit and completeness |
Does the CT measurement meet the VDA requirements?
Yes. VDA Volume 2 recognises industrial CT as a testing method provided that the measurement methodology is documented in a verifiable manner [1]. To this end, Microvista states the following in every test report:
- Calibration and traceability of measuring equipment,
- Verification of measurement capability using test specimens scanned along with the image (image quality test specimens and spherical rods),
- CT parameters: voxel size, scan parameters, analysis algorithm,
- Specific indication of the remaining measurement uncertainty.
We assign an internal number to every component upon receipt. Scan data, analyses and reports are linked to this number, ensuring that every step in the process is fully traceable. Microvista is ISO 9001:2015 certified.
Creating a first-article inspection report: the sampling process at Microvista
The supplier may only submit the initial sample inspection report once all inspection characteristics are within tolerance; in the event of any deviations, the initial sampling process will be repeated until the evidence is complete. We scan subsequent samples to ensure comparability using identical parameters.
Enquiry
You send drawing, inspection plan and timeline. First assessment within one working day, followed by a binding quote.
Goods-in and scan
Your first articles arrive at our CT lab and are registered with an internal number. Parts up to 715 mm envelope, 1,600 mm length, 150 kg.
Evaluation
Dimensions, porosity, wall thicknesses and joints, inspected to your customer's specifications and the agreed standard.
Report
Measurement records, pore reports and false-colour renderings, provided in the InspectHub online portal, accessible in your browser.
Microvista’s 3 service models
If an initial sample is required, please send us the drawing and your proposed timeline. You will receive a response within one working day regarding feasibility, price and delivery date. The initial assessment is free of charge and non-binding.
Contact form
Microsoft Teams Meeting
Contact person for immediate support
Jonas Wengerodt
Sales Manager
Dr. Robin Höhne
CEO | Microvista GmbH
Frequently Asked Questions
A CT scan starts at €125 (for components with a scan length of up to 200 mm); a manually generated 3D porosity report costs €130 per component. The total price depends on the component size, resolution and scope of the inspection. You will receive a fixed-price quotation in advance.
Yes. VDA Volume 2 recognises CT as a measurement method provided that calibration, measurement capability and measurement uncertainty are documented [1]. This information forms part of every Microvista test report and meets the requirements of your quality management system.
A new first-article inspection report is drawn up for new parts, new suppliers, changes in materials, modified production processes or tools, relocation of production facilities, and following a prolonged production halt. The criteria for this are set out in VDA Volume 2 or the customer agreement.
Initial sampling refers to the entire approval process between the supplier and the customer. The inspection of the initial samples is the metrological part of this process, and the report documents the results of this inspection for the purpose of the approval decision.
In particular, suppliers to the automotive and e-mobility industries, foundries, and companies in the medical technology and aerospace sectors: wherever customers require approval in accordance with VDA Volume 2, PPAP or comparable regulations.