Apple's first foldable smartphone, the iPhone Duo, is facing quality issues due to reports of screen damage near the hinge. According to Mac Rumors, cited by ZDNet, persistent hinge problems during development forced Apple to replace its primary and secondary suppliers. Industry insiders suggest that Apple may need to redesign the hinge to address these defects.
Reportedly, screen damage seems concentrated near the hinge. Reuters adds that iFixit identified possible causes of damage through 3D hinge simulations based on teardown videos, patents, and CT scans. The analysis suggests that the central support rod may not retract properly during folding, putting stress on the inner screen.
According to Trend Force, the waterdrop hinge of foldable phones must serve two functions: providing stable support when unfolded and retracting when folded to allow sufficient bending space for the screen. If the support structure fails to retract properly, it can create localized stress, damaging the screen. Preliminary market feedback and teardown analyses indicate that this mechanical issue is the primary concern.
Meanwhile, Mac Rumors reported on October 26 that Apple acknowledged issues with the inner screens of some iPhone Duo units. The company did not disclose the cause of the screen cracking or whether there are plans for a fix. Mac Rumors noted that affected users can already exchange their devices at Apple retail stores, but some may need to wait due to limited stock.
Challenges Facing Hinge Suppliers and Production Constraints
Hinge-related challenges emerged early in the R&D phase. According to ZDNet, US-based Amphenol was initially the primary hinge supplier, with Taiwan's Xin Zusheng as the secondary supplier. Later, due to Amphenol's production falling far short of expectations, Xin Zusheng took over hinge supply. However, Xin Zusheng reportedly also encountered difficulties in production, having to select hinge units that met Apple's quality standards as "golden samples." These challenges led to delays in iPhone Duo production.
In this context, News Pim reports that Apple has asked Foxconn and its component suppliers to increase the iPhone Duo shipment target for the next 12 months by 44%, from 9.7 million units to 14 million. Industry insiders believe this production increase reflects both stronger-than-expected initial demand and increased component inventory to cope with potential assembly defects. The report notes that Foxconn's final assembly yield rate in September was around 60%, and hinge-related defects could further drive up demand for replacement OLED panels.
Trend Force points out that early reports of screen failures could undermine consumer confidence in Apple's highly anticipated new product launch, especially among first-time foldable phone buyers. However, the long-term impact largely depends on the prevalence of the issue and Apple's ability to quickly identify the root cause and repair or replace affected devices.
Additionally, another potential supply bottleneck is T-glass fiber, a high-end glass fiber yarn used in copper-clad laminates (CCL) for printed circuit boards (PCBs). As reported by ZDNet, Japan's Nitto Boseki nearly monopolizes the production of T-glass fiber and prioritizes shipments for AI chips produced by companies like NVIDIA, which could put pressure on Apple's supply chain.