Apple’s long-rumoured foldable iPhone may have hit another speed bump. New reports claim development has stalled over durability problems with the device’s hinge mechanism.
According to leaker Instant Digital on Weibo, Apple’s foldable – tipped to launch as the “iPhone Ultra” – is currently struggling to pass the company’s internal reliability tests.
The issue reportedly centres on the hinge failing to withstand prolonged, repeated folding consistently.
That probably isn’t too surprising. While the best foldable phones have improved massively over the past few years, hinge durability and display creasing remain two of the category’s biggest weaknesses.
The hinge itself is reportedly one of the most advanced parts of the device. Previous supply chain reports suggested Apple plans to use Liquid Metal, also known as metallic glass, within the hinge structure. The material is believed to be more resistant to bending and deformation than traditional metals. At the same time, it will also be tougher than titanium alloy.
Apple has reportedly experimented with the material for over a decade, though the company has only used it in tiny components like SIM ejector pins until now. The foldable iPhone would mark its first major use in a critical moving part.
Interestingly, the report claims Apple has largely accepted that some level of display crease is unavoidable. Instead, the company appears focused on making the crease effectively invisible during normal use over the long term. Earlier leaks suggested Apple had already achieved crease depths below 0.15mm. It also revealed a specially designed dual-layer ultra-thin glass structure intended to better distribute stress across the display.
Despite the reported production hiccup, sources suggest the foldable iPhone’s launch window hasn’t shifted dramatically yet. Apple still plans to begin mass production in mid-2026 and unveil the device alongside the iPhone 18 Pro lineup next September.
As for the hardware itself, rumours suggest the foldable will feature a 7.8-inch inner display, a 5.5-inch outer screen, an A20 chip, dual rear cameras, and a Touch ID-enabled power button instead of Face ID. Pricing, unsurprisingly, is expected to be steep. Rumours point to a starting price of around $2000.
