First Article Builds: Building It Right from the Start

At Applied Engineering San Jose, we know that the first production run sets the tone for everything that follows. A First Article Build isn’t just about proving a design—it’s about confirming that every piece of your product, process, and documentation is ready for real-world manufacturing.

Whether you're preparing to launch a medical device, a clean technology solution, or a precision instrument, the First Article Build is a critical step in getting it right the first time.

What Is a First Article Build?

A First Article Build is the first production-intent version of your product—manufactured using the actual materials, tooling, and processes that will be used in scaled production. It's more than a final prototype; it’s a full validation step designed to ensure your product is manufacturable, repeatable, and compliant.

At Applied Engineering, this isn’t done in isolation. It’s embedded into our broader New Product Introduction (NPI) process, and supported by our Build to Print Plus approach—where we provide design insight, manufacturability reviews, and process expertise from day one.

Why First Article Builds Matter

A successful first article build helps avoid surprises, reduce rework, and create a clear path to production by:

  • Verifying product documentation
    Ensuring BOMs, tolerances, and drawings are complete, accurate, and build-ready.

  • Confirming manufacturing feasibility
    Testing whether your product can be produced at scale using intended processes and materials.

  • Catching early-stage risks
    Identifying issues with fit, assembly, tooling, or supply chain before they impact production.

  • Supporting traceability and quality
    Enabling data-driven validation with First Article Inspection Reports (FAIRs) and full compliance documentation.

Our Approach: More Than a Checkpoint

At Applied Engineering, we treat the First Article Build as a foundational phase—not a checkbox. Here’s how we execute it as part of our integrated process:

1. Front-End Alignment
Our engineering, quality, and production teams collaborate early to review designs, documentation, and build expectations. This early engagement—core to our NPI process—ensures clarity before production starts.

2. Production-Intent Setup
We build your product using the actual tools, materials, and processes intended for production. This real-world setup is essential for evaluating true manufacturability.

3. Detailed Evaluation and Reporting
During the build, we inspect critical features, validate tolerances, and document findings. If needed, we generate a full FAIR package and provide structured feedback on opportunities to refine design or process.

4. Continuous Feedback and Refinement
Leveraging our Build to Print Plus capabilities, we don’t just report issues—we work with your team to solve them. From DFM recommendations to process adjustments, our goal is to improve outcomes without changing your core design intent.

5. Readiness for Ramp
Once the first article is approved, we’re ready to scale. Because everything from sourcing to assembly to documentation has been stress-tested, the transition into production is smoother, faster, and more predictable.

Where Quality and Scalability Begin

First Article Builds represent the critical handoff between design and production. When done right, they give you confidence—not just in the product, but in the entire manufacturing strategy behind it.

By embedding the FAB into our NPI workflow and supporting it with Build to Print Plus insight, we help customers bring products to market with fewer risks and greater success.

Let’s Build It Right the First Time

If you're preparing for a product launch, don't let the first build be an afterthought. Make it a strategic step with Applied Engineering San Jose—where first articles lay the foundation for manufacturing excellence.

Tim DeGrasse