Apple's foldable iPhone halted by hinge failures, production stalls

Apple's foldable iPhone, likely called the "iPhone Ultra," has hit a major roadblock with its hinge design, stalling trial production as the company struggles to meet its own quality control standards.

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The issue centers on the hinge's durability under high-frequency use, a critical flaw that could delay the device's launch. Leaker "Instant Digital" revealed that the hinge is failing to maintain structural integrity over time, leading to mechanical wear that Apple deems unacceptable.

The company is reportedly using Liquid Metal (also known as metallic glass) in the hinge for the first time in a major component, a material known for its resistance to deformation and improved durability. Despite this, the hinge remains the primary bottleneck in the foldable's development.

I reported on Apple's strict requirements for its foldable iPhone back in March, 2025, where it was reported liquid metal hinges were being used for the device, and that its implementation is intended to solve the dreaded crease problem across all foldable devices.

Apple has been working on foldable technology for years, and the hinge has always been a focal point. The company's stringent standards for reliability and user experience are now working against its timeline. While some reports suggest a fall 2026 launch is still on track, the delays highlight the complexity of foldable engineering and Apple's perfectionist approach.

With competitors like Samsung and Huawei already dominating the foldable market, Apple's delayed entry could give rivals more time to innovate and capture consumer interest. If the hinge issue isn't resolved soon, the iPhone Ultra/Fold may miss a critical window to redefine the category.