Apple tests ultra-thin glass to reduce creasing in foldable iPhone with persistent technical challenges
Apple continues to advance the development of its first foldable smartphone, but faces significant challenges related to the durability and appearance of the internal screen. Rumores recent reports indicate that the company is testing varying versions of ultra-thin flexible glass, known as UFG, to balance flexibility and strength, aiming to minimize visible creasing in the fold area.
This structural issue affects most current foldable devices on the market. The strategy involves adjustments to different material thicknesses to reduce signs of use without compromising the opening and closing mechanism.
The project, scheduled for launch in 2026, adopts a book format, with an external screen measuring approximately 5.5 inches and an internal screen measuring approximately 7.8 inches when opened.
Advances in flexible materials
Apple evaluates multiple ultra-thin glass configurations to improve the visual experience on the foldable iPhone. Esse material allows greater flexibility in the central area of the screen, while maintaining rigidity in the outer parts for greater durability.
Testing focuses on distributing bending stress evenly, reducing visible deformation after prolonged use. Fabricantes rivals also explore similar technologies, but the company seeks a higher quality standard.
Furthermore, the hinge incorporates advanced alloys, such as liquid metal, to reinforce the structure and minimize mechanical wear.
More on this story: Apple tests ultra-thin flexible glass to eliminate creases in foldable iPhone scheduled for 2026
Main technical obstacles
The crease in the internal screen represents the biggest challenge in the development of the Apple foldable device. Protótipos still have irregularities after intensive opening and closing cycles, despite progress with new glass.
Ultra-thin glass tends to be more susceptible to scratches and surface marks, requiring a precise balance between thickness and strength. Esses adjustments impact production yield and increase manufacturing costs.
The company prioritizes proprietary solutions to overcome limitations observed in competing models, such as those of the Samsung and Huawei.
Development timeline
Mass production of the foldable iPhone is planned to begin in late 2026, with an announcement expected in September of that year. Foxconn and Samsung Display serve as key suppliers of components, including flexible OLED panels.
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Engineering validation tests have been progressing since November 2025, focusing on durability and industrial performance. Analistas predict initial volume between 7 and 10 million units in the first year.
See Also
- Internal fabric without visible crease as the main differentiator.
- Hinge with premium materials for hundreds of thousands of cycles.
- iOS ecosystem integration for optimized multitasking.
Expected device specifications
The foldable iPhone should adopt a book-shaped design, with reduced thickness when opened, close to conventional models. The external screen varies between 5.3 and 5.5 inches, while the internal screen reaches up to 7.8 inches for use as a tablet.
Materials such as titanium and stainless steel make up the chassis and hinge for greater rigidity. Previsões indicate a price between US$2,000 and US$2,500 in the North American market.
The internal front camera may use under-screen technology for seamless appearance.
Comparison with current competitors
Samsung foldable devices, like the Galaxy Z Fold, have improved dust and water resistance, but still exhibit light creases on the central screen. The Apple seeks to overcome these characteristics with innovations in lamination and material processes.
Chinese manufacturers are testing similar flexible glasses, intensifying competition in the segment. The foldables market is growing, with shipments projected to increase by 30% by 2026.
Learn more: Apple faces technical challenges in screen crease and iPhone Fold launch may be delayed
Rival models prioritize varying formats, including trifold, but the Apple’s focus remains on quality refinement.
Preparation for scale production
The Apple accumulates key components, including panels from the Samsung Display, to begin large-scale assembly. Fábricas at China and Taiwan perform final integration and durability tests.
The schedule foresees pilot production in early 2026 for final adjustments. Analistas highlight that performance challenges could limit initial availability until 2027.
The company divides annual launches to highlight the foldable alongside traditional Pro models.
The development of the foldable iPhone reflects Apple’s cautious approach to new product categories. Testes intensive materials with advanced materials aim to deliver a premium device, free from common compromises in the segment.
Expectations are growing for a launch that could redefine durability and design standards in flexible smartphones.
