iPhone Ultra: Hinge reportedly ready for mass production Apfelpatient

One of the biggest question marks surrounding Apple's first foldable iPhone appears to have been resolved. A new supply chain report identifies the specific weaknesses in the hinge – and declares them largely fixed.

The hinge was long considered the most critical component of the iPhone Ultra, as it determines the folding feel, the gap appearance, and the device's durability. Apple was reportedly struggling with this issue recently – but a recent report from Asia now states that the problems surrounding the 3D-printed hinge module have been resolved and the device has entered the next production phase. This further strengthens the overall picture surrounding Apple's first foldable device, pointing towards a market launch later this year.

What was wrong with the hinge?

The report by the Korean trade publication The Elec provides more concrete details about the problems for the first time. According to the report, difficulties arose with the hinge during the actual development process. A Taiwanese industry representative is quoted as saying that after millions of durability tests, a slight noise was heard coming from the hinge. Furthermore, tolerances in some assembly steps were larger than expected, resulting in a noticeable increase in the reject rate.

Most of these problems have now been resolved, it is said. This aligns with earlier reports that Apple wanted to ensure both the durability of the mechanism and the smoothest possible folding process – requirements that were considered one reason for the temporary production stalls. Similar care was already evident during the development of the mechanism, for example in the tests involving a liquid metal hinge and early prototypes with network operators.

Two suppliers behind the module

According to the report, the hinges come from two suppliers: the Taiwanese company Shinjuxing and the US manufacturer Amphenol. Both supply the 3D-printed hinge modules that enable the display to open and close. This additive manufacturing process allows for more complex geometries than conventional methods, but places higher demands on consistent dimensional accuracy when mass production is reached – which likely explains the reported tolerance issues.

Entry into test production

Evidence of progress is that, according to the report, the device has entered test production. This phase is the final quality control step, verifying that everything is running smoothly on the actual production lines before mass production begins. Once a product reaches this point, the fundamental design hurdles have usually been overcome.

Why Apple is playing it safe with the foldable

Quality issues would have been particularly critical for Apple in this case. The company waited an unusually long time to enter the foldable market – reportedly precisely because it wanted to ensure that the weaknesses of competing models wouldn't also affect the iPhone Ultra. An audible hinge noise or an increased defect rate would have directly contradicted this claim, which is why addressing these issues is considered a crucial prerequisite for a market launch this year.

September start is within reach

While reports of possible delays until December or even next year circulated at one point, the latest reports unanimously point to a presentation during the September keynote, with a sales launch shortly thereafter. If the resolved hinge issues prove to be permanent, this would eliminate the last major technical argument against a fall launch of the most expensive iPhone to date. (Image: Shutterstock / AlexandrBognat)