In general, first article testing (FAT) is a comprehensive testing process that verifies the conformance of a new or modified product with specified design requirements and quality standards. This involves thorough inspections, testing, and evaluation to identify any discrepancies or deviations from the established requirements. In our case with military batteries, a FAT ensures that a lithium battery conforms to military specifications (see Specifications) such as MIL-PRF-32271 for primary lithium batteries. The testing requirements are guided by industry standards, but ultimately defined by the standards of the military which require batteries to have an especially robust and reliable design capable of operating in a military environment. If a manufacturer wishes to obtain a contract with the government to provide any one type of military battery, they must first produce an initial lot that successfully completes FAT.
Before testing is conducted, the manufacturing company must create a first article test plan that is reviewed and then approved by the government. After approval of the test plan, the company will create their first lot of cells and batteries. From these, a random set of samples are selected for testing. Once the samples successfully pass FAT, a government contract can be given to the manufacturing company allowing them to mass produce subsequent lots expected to adhere to the same specifications. If there is a change in design of the cell or battery, change in material, or a change in processes or facilities, a new first article must be conducted and successfully completed again.
Overall, FAT helps us ensure consistency and quality in the production of military batteries. It serves as a vital part in the quality assurance process, providing a solid framework to validate newly developed batteries before they enter mass production and distribution.