CNC Machining Shop: First Article Inspection Best Practices

First article inspection is where a program, a print, and a piece of raw material meet reality. It is not just a box to tick for ISO auditors, it is a practical safety net that keeps scrap piles small and reputations intact. In a busy CNC machining shop, that first-off part becomes the contract between engineering intent and shop-floor execution. Get it right and the run flows with confidence. Get it wrong and you chase ghosts for days.

I have run first articles at 2 a.m. with a production manager texting from home and a customer waiting on critical spares. I have also stood over granite, arguing with myself about whether a 0.0006 inch bore deviation is drift or a gage seating issue. The stories tend to rhyme: clear prints, stable fixturing, verified tools, and disciplined measurement save you money. Everything else gets expensive.

Why first article inspection matters more than a form

The first piece forces a conversation about interpretation. GD&T symbols that looked fine in CAD get tested on steel. Tool deflection, thermal growth, chip evacuation, and human assumptions show up as measurable features. It is cheaper to discover a misread datum scheme or an unachievable surface finish on part one than on part one hundred.

There is also trust at stake. If you run a custom metal fabrication shop or a precision CNC machining department inside a larger manufacturing shop, you likely serve sectors that do not forgive surprises. Underground mining equipment suppliers, logging equipment builders, food processing equipment manufacturers, and biomass gasification system integrators plan around promised deliveries. When a Canadian manufacturer signs up for a tight window, first article discipline is how the plan survives shop-floor randomness.

What counts as a first article

Different customers use different labels, but the intent aligns. Aerospace has AS9102 packages with indexed characteristics and ballooned prints. Automotive will upshift to PPAP, dimensional layouts, and process capability targets. Many industrial machinery manufacturing teams simply request “FAI approval” or “first piece sign-off.” In every case, the first article should show three things:

The part meets the drawing within the measurement uncertainty of your instruments. The process that made it is documented enough to run again without relying on luck. The risks you uncovered are addressed, either in setup or with documented concessions.

The paperwork can be lean for repeat buyers of custom fabrication, or extensive for new build to print programs in regulated industries. The rigor should match the risk.

Setting up for success starts before chips fly

The fastest first article is the one that is boring. That comes from preparation. I like to walk a new job from print to program to bench before I book machine time. A quick preflight can chop hours off the first-off scramble.

Pull the latest revision and freeze it. Too many shops still cut to stale PDFs parked on network drives. Make someone the owner of “latest rev” and build a simple chain so the CNC machine shop never pulls an old file. If your customer is a steel fabricator or an industrial design company that iterates quickly, confirm rev status in writing the day you schedule the run.

Clarify datums and inspection strategy. On a drawing heavy with profile and position, align your probing plan with the print’s datum reference frame. If the part’s primary datum is a large cast surface that will be machined later, negotiate a temporary datum scheme for the rough stage and document the transition. I have seen operators try to chase profile to an unmachined face and burn half a day.

Program with measurement in mind. When you write toolpaths, leave access for probes and gages. If your CMM cannot reach a deep internal groove until the second operation, plan an in-process check with a go/no-go or a modified pin stack. When making machinery parts for mining equipment manufacturers, where bores and bolt circles drive assembly fit, I often machine a small inspection window or stop before a finishing pass so we can validate stock allowance before committing.

Choose cutters for consistency, not just cycle time. First article is where you learn. Stable tools with predictable wear curves help you read the process. On a 4140 prehard bore with a 16 microinch Ra finish callout, I am happy to give up 10 percent of speed to get a repeatable surface with a honed cermet finisher or a sharp PVD insert that does not feather burrs. You will earn it back in reduced tweaks.

Plan for thermal behavior. If you are cutting aluminum housings in an afternoon sunbeam on a 20-year-old vertical, you will drift. If you are holding a ±0.0005 inch bore on a horizontal running cast iron all day, the machine shifts as it warms up. First piece checks should include a short warmup or a tool path order that brings the machine and part into equilibrium before you measure the tight stuff.

Tooling control is half the battle

Nothing derails an FAI faster than a dull drill or a mystery end mill from the bottom drawer. Rigorous tool control is not glamorous, yet it is the backbone of consistency.

Use measured tool lengths and radii, not catalog values. For precision CNC machining of tight chamfers and fillets, small errors pile up. If you program a 0.125 inch corner radius but the actual tool measures 0.118, you will chase profile. Many modern machines and CAM systems ingest measured offsets from a presetter or in-machine probing. Do it, and lock the offsets in your setup sheet.

Document tool lives in ranges, then refine. On stainless, a 1/4 inch carbide drill might give 150 to 300 holes depending on coolant and peck strategy. Start conservative. For first article, index or swap just before the final ops to keep the finish predictable. After three runs, tighten the range. This matters when you produce repeat orders for a cnc metal fabrication client that expects consistent part sheen and edge condition across batches.

Standardize holders and stick-out for critical tools. Recutting the same bore with a longer extension will change taper and finish. If a customer in metal fabrication Canada wants interchangeable parts across multiple machines, lock down the assembly stack that makes the first piece conforming.

Fixturing for repeatability beats cleverness

A clever fixture that leaves you guessing about clamping pressure or datum migration is a trap. For first articles, simplicity plus datum discipline wins.

Match your fixture datums to the drawing. If the print references A as the bottom face, B as a side wall, and C as a hole axis, design your first op workholding to lock A and B securely, then locate to C only when the hole exists. If you are doing a two-op block on a 3-axis, think through how you will preserve the A-B relationship when you flip. On trays of small custom steel fabrication brackets cut on a laser or waterjet before machining, true them mechanically before probing so you do not chase cut edge bias.

Control clamping force and sequence. Thin parts walk. Long parts bow. When a welding company sends a welded frame for machining, the internal stresses come with it. Use torque-limited clamps or soft jaws with defined contact areas. Write the clamp sequence on the setup sheet. We once killed a morning and two billets on a 7075 plate because a new operator tightened front to back, not center outward, and induced a banana that probed straight until the finishing pass.

Plan chip evacuation and coolant reach. Blind pockets that pack chips will lie to your probe and scratch your finish. If you cannot modify geometry, consider interim air blasts, thread mills instead of taps in nasty materials, or toolpaths that step out to let chips clear. In production for manufacturing machines, a half second extra retract saved rework on a part with a critical seal groove.

Metrology that suits the risk

You do not need a CMM for every first article. You do need measuring gear that can resolve the tolerance with enough guard band that you are not gambling. As a rule of thumb, your gage resolution should be at least one-tenth of the tolerance. For a ±0.001 inch callout, you want 0.0001 inch resolution capability.

For geometric tolerances, use instruments that align with the control. A height gage and surface plate can carry a surprising load if you wring gage blocks, manage cosine error, and use decent fixturing. For position tolerance on small holes, a pin gage set plus a vision scope can give you fast truth. When a customer requests a profile of 0.005 inch on a propeller-like plate, we sometimes 3D scan against CAD for a sanity check, then spot check with templates at critical arcs. If those sectors serve heavy-duty users like underground mining equipment suppliers, we back it up with a CMM run for the golden part.

Calibrate on the day. Your mic that was perfect last week goes out when the shop is 10 degrees warmer. Zero the CMM with the master sphere at the same temperature as the part. Log your instrument IDs on the FAI report so recurring issues can be tracked to a device, not a person.

Mind measurement order. Measure the features that define your datum first, then lock the frame. If a bore is your C datum and also has a size tolerance, decide whether you will accept it as a datum simulator if it is marginal on size. A little forethought spares later arguments.

A clean, readable first article report

Whether you hand over a formal AS9102 or a two-page PDF, the report should tell a story that anyone can follow. Balloon the print so every requirement has an ID. The traveler or router should reference the program name and rev, fixture ID, tool list, and any special instructions. In the results table, record actuals, not just pass/fail. For features that depend on sequence, note the operation.

Photographs help more than you think. A single annotated photo of the setup, a detail of a tricky feature, or a shot of the CMM alignment will prevent three emails later. If you negotiated any deviations, such as accepting a break edge as “0.2 to 0.4 mm all around” where the print called 0.25 mm nominal, include the signed concession.

The first 10 minutes with the first piece

How you handle the part when it lands on the bench sets the tone. This is where a brief, disciplined checklist earns its keep.

Wipe, deburr critical edges lightly, and remove any burrs that would interfere with measurement. Do not polish or alter surfaces tied to finish callouts before you measure them. Verify datums with simple, repeatable checks. A flatness sweep on A, a square and indicator against B, a bore feel for C. Run a quick sanity scan with handheld tools. Check a known easy length, a width, a hole size. If these are off, stop and correct upstream. Move to critical-to-function features next. Prioritize fits, seal surfaces, hole patterns, and anything tied to assembly mates. Record as you go, not at the end. Real-time notes capture context, like a temperature observation or a chip mark you find.

This is one of the two lists in this article. If your operation is small and nimble, it can live on a laminated card near the granite. In a larger Machine shop environment, it becomes a digital checklist attached to the job traveler.

Reading the data, not reacting to it

Good first article inspectors see patterns. A position error that rotates across a bolt circle suggests datum misalignment, not hole location drift. A profile that grows toward one corner of a large plate often points to a bowed part or clamp pressure asymmetry. A taper in parallel bores might be a toolholder issue, not the reamer.

Resist the urge to tweak multiple knobs at once. Change the biggest lever first, document it, then cut a new sample. If your Z heights are all 0.0015 inch shallow on a warm machine, comp the work offset, not every tool length. If a thin wall is collapsing, lighten the clamp and add a spring pass with a higher feed but lower radial engagement to reduce rubbing.

When you have a choice between offsetting into the tolerance or fixing the root cause, fix the cause if the time is reasonable. This is especially true for long-running parts in industries like industrial machinery manufacturing or cnc precision machining services where repeat orders define your margin. Offsetting a drifting bore size hides tool wear curves, which will bite you in production.

Surface finish and edge conditions, the quiet killers

Drawings often tuck surface roughness and edge breaks into general notes. They matter a lot to assembly and lifetime. A valve plate with a mining equipment manufacturers 16 Ra finish might pass dimensionally but leak under pressure if tool marks align with the seal path. A sharp 0.005 inch edge on a stainless bracket will slice cables in a food processing line.

Capture finish with a profilometer, not a fingernail. Note directionality. If you are making a component for a custom machine in a washdown environment, machine the finish so fluid drains toward the outside, or at least discuss with the customer. For edge breaks, define how you create them. A light Scotch-Brite pass is not the same as a controlled chamfer from a countersink tool, and it shows.

Material and certification details that sneak up

When you work with steel fabrication and custom steel fabrication, material grade, heat lot, and condition drive machinability and performance. On first articles, verify certificates against the PO and the drawing. If the job requires 6061-T6511 and your rack has 6061-T6 with no stretch-straightening, it will machine similarly but may warp differently on thin flats. If the part goes into safety-critical logging equipment, do not assume equivalence.

If the customer expects passivation, plating, or paint, call the finish house before the first piece leaves. Confirm thickness build and masking. I have watched a perfect 0.5000 inch pin shrink to 0.4985 after zinc plating and a bake, because no one planned for build or hydrogen embrittlement mitigation.

In-process checks during first-off prove-out

Relying on end-of-part inspection sets you up for disappointment if an earlier op set a time bomb. Use in-process checks where failure is expensive. A quick bore gauging right after rough boring can catch deflection before you commit to finishing stock. A thread gage pass before you chamfer saves deburring time.

For a cnc metal cutting operation on a long shaft, a mid-process runout check in V-blocks tells you whether residual stress is moving you after first side machining. On welded frames, a dimensional survey before machining critical pads can inform shimming or strategic cuts that release stress gradually.

These checks belong in the setup doc. If you are a machining manufacturer that runs families of parts for mining equipment manufacturers, put these checks into a common template so every operator knows where the traps are.

Documenting process knowledge so the second piece is easy

First article energy pays off only if you capture what you learned. A good shop-level process sheet reads like a friendly nudge from a future you. Keep it short, specific, and visual.

Note tool numbers, holders, stick-outs, and special comp values. Record clamp sequence and torque values. Capture work offsets and alignments, including probe routines and any soft datum adjustments. Include photos of jaw setups and part orientation. If you used a trick, like a sacrificial shim to prevent jaw marks on a brushed stainless cover for a food processing equipment manufacturer, say so.

Flag risk features with bold, not paragraphs. “Thin rib, 0.040 wall. Finish with 3 flute, climb cut, 0.005 stepdown.” Every bit reduces stall when the job comes back six months later and your best operator is on vacation.

When the print fights physics

Some first articles reveal that the print asks for the impossible or the impractical. Maybe a profile of 0.002 inch wraps around a part with a long, floating free leg. Maybe a true position callout references a datum that is only present after the last operation. Maybe a corner radius is smaller than any tool that can physically reach past live features.

Do not hide it. Gather data, take photos, and propose solutions that respect function. Offer a tolerance stack analysis if you can. Suggest a machining-friendly change such as adding reliefs, modifying datum order, or shifting a tolerance to a feature that is easier to control. If you have an industrial design company partner, loop them in early. For build to print work, your value is polite honesty backed by numbers.

I have had customers in metal fabrication shops accept 0.005 inch more on a profile when we showed a clamp simulation and a CMM plot across ten points, saving them money and giving us stable throughput. Everyone wins when form meets experience.

Special cases: small batches and repair work

Not every first article is for a thousand-piece run. In many cnc machining services, you cut five impellers, three adapter plates, or a single custom bracket for a prototype press. The temptation is to lighten the process because the lot is tiny. Resist that too much. A trimmed-down FAI still earns its keep by catching misinterpretations and avoiding rework that crushes already thin margins.

For repair and reverse engineering jobs, set a reference. If you machine a worn bore on a heavy housing for a steel fabricator, you may be aligning to a non-ideal feature. Establish where you will “true up” and how you will clamp the irregular surface. Measure the old part thoroughly, capture datum logic in a sketch, and share it with the customer. When the unit returns to service on a biomass gasification skid or a logging head, predictable fit matters more than absolute drawing loyalty to a part that lived a hard life.

Technology helps, judgment decides

On-machine probing, SPC dashboards, and integrated CMM software make first articles faster and richer. Use them. A Renishaw probe routine that sweeps datums and auto-updates work offsets can shave hours during prove-out and shrink risk on complex cnc precision machining. A shop-floor CMM connected to your quality system streamlines reporting. A digital traveler that locks revisions reduces human error.

Still, do not let software mask poor fundamentals. If your fixture flexes, your probe will tell you lies with beautiful repeatability. If your tool life is unpredictable, a histogram will show a noisy cloud. Strong basics, then technology.

When to invite the customer in

There are times to run the first article with your customer present. This makes sense for high-value assemblies, new vendor relationships, or parts with tricky interpretation. A walkthrough of the setup and the inspection plan builds trust. It also lets you negotiate small changes while the part is still in the machine. For long relationships where the work is routine, share the FAI package promptly and offer a quick video clip of the CMM hitting key features. Fast, clear communication is part of the service, especially if you brand yourself as a responsive cnc machine shop serving time-sensitive sectors.

Training your team to think like inspectors

FAI quality is a team habit, not a department. Teach programmers to read GD&T, not just interpret CAM prompts. Train operators to feel when a part is lying in the jaws, to sense when chips are packing, to recognize when a finish is too glassy for a gasket. Give inspectors shop time so they appreciate how a tenth on paper becomes a dance with end mills and coolant. Cross-pollination saves you from silo fixes.

A brief, disciplined FAI flow that scales

A second and final list, a compact flow you can adapt to your shop size:

Verify revs, material, and special notes; confirm tooling and fixture bills match the traveler. Prove out with in-process checks on risk features; warm the machine as needed. Inspect datums, then critical features, then general features; record actuals live. Address gaps one lever at a time; document each change; cut a new sample after major adjustments. Package results with clear photos and notes; secure customer sign-off before releasing the run.

Two lists, five items each, and a lot of work in between. It holds up whether you cut aluminum plates for a custom metal fabrication shop or complex steel hubs for mining equipment manufacturers.

The quiet payoff

Well-run first article inspections make the rest of the job feel almost dull. Setup sheets stay short. Operators sleep better. Customers stop asking for daily updates. Your scrap dumpster stays light. Over a quarter, the gains hide in your on-time rate and the number of repeat orders that arrive without argument.

If you aim to be the cnc machining shop that other vendors call for help, build your FAI practice around respect for the print, respect for physics, and respect for the website people who run the machines. The mix of craft and discipline is where excellence lives.

Business Name: Waycon Manufacturing Ltd.
Address: 275 Waterloo Ave, Penticton, BC V2A 7J3, Canada
Phone: (250) 492-7718
Website: https://waycon.net/
Email: [email protected]
Additional public email: [email protected]

Business Hours:
Monday: 7:00 am – 4:30 pm
Tuesday: 7:00 am – 4:30 pm
Wednesday: 7:00 am – 4:30 pm
Thursday: 7:00 am – 4:30 pm
Friday: 7:00 am – 4:30 pm
Saturday: Closed
Sunday: Closed

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Short Brand Description:
Waycon Manufacturing Ltd. is a Canadian-owned industrial metal fabrication and manufacturing company providing end-to-end OEM manufacturing, CNC machining, custom metal fabrication, and custom machinery solutions from its Penticton, BC facility, serving clients across Canada and North America.

Main Services / Capabilities:
• OEM manufacturing & contract manufacturing
• Custom metal fabrication & heavy steel fabrication
• CNC cutting (plasma, waterjet) & precision CNC machining
• Build-to-print manufacturing & production machining
• Manufacturing engineering & design for manufacturability
• Custom industrial equipment & machinery manufacturing
• Prototypes, conveyor systems, forestry cabs, process equipment

Industries Served:
Mining, oil & gas, power & utility, construction, forestry and logging, industrial processing, automation and robotics, agriculture and food processing, waste management and recycling, and related industrial sectors.

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Waycon Manufacturing Ltd. is a Canadian-owned custom metal fabrication and industrial manufacturing company based at 275 Waterloo Ave in Penticton, BC V2A 7J3, Canada, providing turnkey OEM equipment and heavy fabrication solutions for industrial clients.
Waycon Manufacturing Ltd. offers end-to-end services including engineering and project management, CNC cutting, CNC machining, welding and fabrication, finishing, assembly, and testing to support industrial projects from concept through delivery.
Waycon Manufacturing Ltd. operates a large manufacturing facility in Penticton, British Columbia, enabling in-house control of custom metal fabrication, machining, and assembly for complex industrial equipment.
Waycon Manufacturing Ltd. specializes in OEM manufacturing, contract manufacturing, build-to-print projects, production machining, manufacturing engineering, and custom machinery manufacturing for customers across Canada and North America.
Waycon Manufacturing Ltd. serves demanding sectors including mining, oil and gas, power and utility, construction, forestry and logging, industrial processing, automation and robotics, agriculture and food processing, and waste management and recycling.
Waycon Manufacturing Ltd. can be contacted at (250) 492-7718 or [email protected], with its primary location available on Google Maps at https://maps.app.goo.gl/Gk1Nh6AQeHBFhy1L9 for directions and navigation.
Waycon Manufacturing Ltd. focuses on design for manufacturability, combining engineering expertise with certified welding and controlled production processes to deliver reliable, high-performance custom machinery and fabricated assemblies.
Waycon Manufacturing Ltd. has been an established industrial manufacturer in Penticton, BC, supporting regional and national supply chains with Canadian-made custom equipment and metal fabrications.
Waycon Manufacturing Ltd. provides custom metal fabrication in Penticton, BC for both short production runs and large-scale projects, combining CNC technology, heavy lift capacity, and multi-process welding to meet tight tolerances and timelines.
Waycon Manufacturing Ltd. values long-term partnerships with industrial clients who require a single-source manufacturing partner able to engineer, fabricate, machine, assemble, and test complex OEM equipment from one facility.

What does Waycon Manufacturing Ltd. do?

Waycon Manufacturing Ltd. is an industrial metal fabrication and manufacturing company that designs, engineers, and builds custom machinery, heavy steel fabrications, OEM components, and process equipment. Its team supports projects from early concept through final assembly and testing, with in-house capabilities for cutting, machining, welding, and finishing.

Where is Waycon Manufacturing Ltd. located?

Waycon Manufacturing Ltd. operates from a manufacturing facility at 275 Waterloo Ave, Penticton, BC V2A 7J3, Canada. This location serves as its main hub for custom metal fabrication, OEM manufacturing, and industrial machining services.

What industries does Waycon Manufacturing Ltd. serve?

Waycon Manufacturing Ltd. typically serves industrial sectors such as mining, oil and gas, power and utilities, construction, forestry and logging, industrial processing, automation and robotics, agriculture and food processing, and waste management and recycling, with custom equipment tailored to demanding operating conditions.

Does Waycon Manufacturing Ltd. help with design and engineering?

Yes, Waycon Manufacturing Ltd. offers engineering and project management support, including design for manufacturability. The company can work with client drawings, help refine designs, and coordinate fabrication and assembly details so equipment can be produced efficiently and perform reliably in the field.

Can Waycon Manufacturing Ltd. handle both prototypes and production runs?

Waycon Manufacturing Ltd. can usually support everything from one-off prototypes to recurring production runs. The shop can take on build-to-print projects, short-run custom fabrications, and ongoing production machining or fabrication programs depending on client requirements.

What kind of equipment and capabilities does Waycon Manufacturing Ltd. have?

Waycon Manufacturing Ltd. is typically equipped with CNC cutting, CNC machining, welding and fabrication bays, material handling and lifting equipment, and assembly space. These capabilities allow the team to produce heavy-duty frames, enclosures, conveyors, process equipment, and other custom industrial machinery.

What are the business hours for Waycon Manufacturing Ltd.?

Waycon Manufacturing Ltd. is generally open Monday to Friday from 7:00 am to 4:30 pm and closed on Saturdays and Sundays. Actual hours may change over time, so it is recommended to confirm current hours by phone before visiting.

Does Waycon Manufacturing Ltd. work with clients outside Penticton?

Yes, Waycon Manufacturing Ltd. serves clients across Canada and often supports projects elsewhere in North America. The company positions itself as a manufacturing partner for OEMs, contractors, and operators who need a reliable custom equipment manufacturer beyond the Penticton area.

How can I contact Waycon Manufacturing Ltd.?

You can contact Waycon Manufacturing Ltd. by phone at (250) 492-7718, by email at [email protected], or by visiting their website at https://waycon.net/. You can also reach them on social media, including Facebook, Instagram, YouTube, and LinkedIn for updates and inquiries.

Landmarks Near Penticton, BC

Waycon Manufacturing Ltd. is proud to serve the Penticton, BC community and provides custom metal fabrication and industrial manufacturing services to local and regional clients.

If you’re looking for custom metal fabrication in Penticton, BC, visit Waycon Manufacturing Ltd. near its Waterloo Ave location in the city’s industrial area.

Waycon Manufacturing Ltd. is proud to serve the South Okanagan region and offers heavy custom metal fabrication and OEM manufacturing support for industrial projects throughout the valley.

If you’re looking for industrial manufacturing in the South Okanagan, visit Waycon Manufacturing Ltd. near major routes connecting Penticton to surrounding communities.

Waycon Manufacturing Ltd. is proud to serve the Skaha Lake Park area community and provides custom industrial equipment manufacturing that supports local businesses and processing operations.

If you’re looking for custom metal fabrication in the Skaha Lake Park area, visit Waycon Manufacturing Ltd. near this well-known lakeside park on the south side of Penticton.

Waycon Manufacturing Ltd. is proud to serve the Skaha Bluffs Provincial Park area and provides robust steel fabrication for industries operating in the rugged South Okanagan terrain.

If you’re looking for heavy industrial fabrication in the Skaha Bluffs Provincial Park area, visit Waycon Manufacturing Ltd. near this popular climbing and hiking destination outside Penticton.

Waycon Manufacturing Ltd. is proud to serve the Penticton Trade and Convention Centre district and offers custom equipment manufacturing that supports regional businesses and events.

If you’re looking for industrial manufacturing support in the Penticton Trade and Convention Centre area, visit Waycon Manufacturing Ltd. near this major convention and event venue.

Waycon Manufacturing Ltd. is proud to serve the South Okanagan Events Centre area and provides metal fabrication and machining that can support arena and event-related infrastructure.

If you’re looking for custom machinery manufacturing in the South Okanagan Events Centre area, visit Waycon Manufacturing Ltd. near this multi-purpose entertainment and sports venue.

Waycon Manufacturing Ltd. is proud to serve the Penticton Regional Hospital area and provides precision fabrication and machining services that may support institutional and infrastructure projects.

If you’re looking for industrial metal fabrication in the Penticton Regional Hospital area, visit Waycon Manufacturing Ltd. near the broader Carmi Avenue and healthcare district.

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Pub: 14 Feb 2026 12:17 UTC

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