Apple’s first foldable iPhone is still moving through development with one part drawing the most concern: the hinge. The component has reportedly not yet met Apple’s internal quality standards, raising the possibility that production could pause temporarily if the issue is not resolved.
The model is widely referred to as iPhone Ultra, although Apple has not confirmed that name publicly. The latest chatter points to a manufacturing test cycle that is still being slowed by hinge durability checks, especially in heavy open-close use and long-term wear scenarios.
Hinge durability remains the main obstacle
For a foldable phone, the hinge is not a secondary detail. It affects how smoothly the device opens and closes, while also shaping long-term durability and the consistency of the display during daily use.
Instant Digital says the core problem lies in how well the hinge holds up after repeated use. In quality control testing, the mechanism has reportedly not maintained the level of performance Apple expects for frequent and extended use.
That is why Apple is said to be unwilling to move forward until the issue is fully resolved. If the weak point remains, the production line could be delayed until a suitable fix is ready.
Liquid metal is still part of Apple’s answer
Apple is also believed to be looking at liquid metal for the hinge mechanism. Ming-Chi Kuo previously described the material as a leading candidate for the company’s first foldable device.
Instant Digital notes that liquid metal is also known as metallic glass. Its irregular atomic structure is said to make it more resistant to bending than traditional metals and more durable than titanium alloy.
Apple has used liquid metal before, but only for small parts such as SIM ejector pins. Applying it to a foldable iPhone hinge would be a much larger and more mechanically important use of the material.
A separate report in January also supported this direction. Apple is said to have explored liquid metal materials for more than 15 years, starting from a licensing agreement with Liquidmetal Technologies in 2010.
The display still faces its own challenge
The hinge is not the only issue Apple is trying to manage. The company is also working to reduce the visible crease in the center of the screen, which remains one of the best-known weaknesses of foldable phones.
Apple is reportedly trying to eliminate the crease without paying much attention to cost. One solution under development is said to involve a two-layer ultra-thin glass structure designed to spread pressure across multiple layers.
Even so, Instant Digital says Apple has now accepted that a slight crease is difficult to avoid. Testing reportedly still shows that the device can maintain a display appearance that looks crease-free over long periods of use.
That approach suggests Apple is taking a practical route. Instead of promising a perfectly crease-free panel, it appears to be focusing on a screen that stays visually clean in normal use.
Launch plans are still in place
Despite the technical hurdles, the hinge issue is not expected to derail the launch plan. Apple’s first foldable iPhone is still said to be introduced alongside the iPhone 18 Pro lineup in the fall of 2026.
Mass production is also reportedly scheduled to begin in July. That timetable has been echoed by MacRumors and suggests Apple is still trying to protect its launch target even as development remains imperfect.
Other leaks describe the device as feeling more like an iPhone than an iPad in use. That detail stands out because the screen is said to be much larger than a standard iPhone, while the product is still positioned as a primary phone.
The rumored specifications point to a 7.8-inch main display, a 5.5-inch cover display, the A20 chip, the C2 modem, Touch ID, and two rear cameras. Those details suggest Apple already has a clear product direction, even if the hinge remains the most basic hurdle on the path to mass production.
