Apple’s long-rumoured foldable iPhone, believed to be launching under the “iPhone Ultra” branding, may have cleared one of its biggest technical hurdles, but fresh leaks suggest another major issue could still delay the device before it reaches consumers.
According to new reports from well-known Weibo leaker Instant Digital, Apple’s first foldable iPhone is now in trial production, indicating the company is moving closer to an official launch. However, while the display technology appears to be impressing internally, the phone’s hinge mechanism is reportedly causing serious reliability concerns.
Apple Reportedly Achieves Crease-Free Display
One of the biggest criticisms of foldable smartphones over the past few years has been the visible crease that appears down the middle of the display where the screen folds.
Devices such as Samsung’s Galaxy Fold series, Google’s Pixel Fold and various handsets from Huawei and Honor have all improved dramatically in recent generations, but most still show at least some visible crease when viewed at certain angles.
According to the latest leak, Apple may finally have solved that problem.
Instant Digital claims Apple’s current prototypes have achieved a “visually crease-free state” with “long-term stability,” suggesting the company has found a way to eliminate the distracting fold line that has plagued foldable devices since the category first launched.
That would represent a major engineering breakthrough and could instantly help Apple differentiate the iPhone Ultra from existing rivals.
For years, industry analysts have suggested Apple delayed entering the foldable smartphone market because it was unwilling to compromise on display quality. Apple has traditionally preferred to wait until technologies mature before entering new product categories, rather than rushing products to market first.
If the leak is accurate, it appears Apple may finally be satisfied with the state of foldable display technology.
The Hinge Could Be the Real Problem
Unfortunately for Apple, solving the display may have simply revealed another challenge.
The same leak claims Apple’s hinge mechanism is currently failing to meet the company’s strict durability standards during long-term testing.
According to the reports, repeated opening and closing of the foldable iPhone is causing excessive wear over time. The hinge reportedly struggles to maintain Apple’s required reliability levels after prolonged high-frequency use.
That could become a serious issue for a foldable device expected to survive years of daily use.
Foldable phones place enormous strain on hinges because they are constantly moving mechanical parts. Unlike traditional smartphones with fixed designs, foldables rely heavily on precise engineering to ensure the screen folds smoothly while protecting delicate internal components.
Even Samsung, which is now several generations into its foldable lineup, has faced durability complaints over hinges and folding displays in earlier models.
Apple is known for applying particularly strict quality control standards to its hardware, so even relatively minor wear issues could potentially delay production until the company is satisfied with the long-term durability.
September Launch Still Possible
Despite the reported problems, the leaks suggest Apple is still aiming for a September launch window for the iPhone Ultra.
Trial production is already underway, and if engineers can resolve the hinge reliability issues quickly enough, mass production could still begin on schedule ahead of Apple’s usual autumn iPhone launch event.
That timing would place the foldable device alongside the expected iPhone 18 Pro and iPhone 18 Pro Max models.
However, the phrase “indefinite delay” has also appeared in some reports, highlighting the uncertainty surrounding the project. If Apple fails to achieve the level of durability it wants, there is every chance the launch could slip into 2027.
At this stage, nothing has been officially confirmed by Apple.
What the iPhone Ultra Could Look Like
Leaks so far suggest Apple’s foldable iPhone will follow a book-style design similar to Samsung’s Galaxy Fold range rather than a clamshell flip phone.
The device is expected to open into a tablet-sized internal display, likely around 7.8 inches, giving users more screen space for multitasking, gaming and video playback.
Reports have also suggested Apple is working on an ultra-premium build using titanium and advanced hinge materials, potentially including “liquid metal” alloys designed to improve strength and reduce wear.
Some rumours claim the foldable iPhone could measure around 4.5mm thick when unfolded, making it one of the thinnest Apple devices ever produced.
Battery life is also expected to be a major focus, with leaks suggesting the iPhone Ultra could include the largest battery ever fitted into an iPhone.
Apple’s Foldable Timing May Finally Make Sense
While many Android manufacturers rushed to release foldable phones years ago, Apple’s slower approach may ultimately benefit the company.
The foldable market has matured significantly since the first Galaxy Fold launched in 2019. Early devices were expensive, fragile and filled with compromises. Modern foldables are far more refined, but durability concerns still remain one of the biggest barriers stopping mainstream buyers from switching.
Apple appears determined to avoid those same mistakes.
If the company really has achieved a crease-free display while also solving hinge reliability, the iPhone Ultra could instantly become one of the most desirable foldable devices ever made.
For now though, it sounds like Apple’s engineers still have work to do before the company is ready to unfold its next big innovation.
Keen tech writer outside of my day job in I.T. and spending time with my family.
