Meaning
A comprehensive quality document verifies that a new or modified injection mould is capable of producing parts that meet all drawing specifications. Compiling a first article inspection report involves measuring every single dimension on the initial parts produced from each cavity of the mould. This document marks the formal hand-off between the mould builder and the production team, proving the tool is ready for commercial runs.
Verification Protocol
Quality engineers measure the initial parts after they have cooled and stabilized to account for the post-mould shrinkage of the polymer. Every single feature on the part print is numbered and measured, including wall thickness, hole diameters, and warp profiles. For multi-cavity moulds, this measurement must be completed for every cavity because subtle differences in runner balance or gate size can cause dimensions to vary between cavities.
The resulting data is recorded in a matrix to confirm that each cavity produces parts within the specified limits.
Tooling Qualification
When dimensions fall outside the allowable limits, the mould must be modified or the process parameters adjusted. This iteration continues until all measurements pass, ensuring the tool is steel-safe before final approval. This process prevents the release of an unproven mould that would generate high scrap rates.
Production Baseline
The approved document establishes the baseline process parameters and part dimensions for all future production runs. Any subsequent change in resin supplier or process temperature requires a re-evaluation against this baseline. This ensures consistency over the product lifecycle.
