iPhone Ultra: Report identifies further production hurdles

Two months before its expected launch, the supply chain is again reporting problems with Apple's first foldable iPhone: issues with the hinge and display durability are said to be slowing down production, and the exact market launch date remains uncertain. This report contradicts accounts from just two weeks ago that described the process as running smoothly.

Few Apple products have generated as many conflicting signals in recent months as the foldable model, whose rumors and facts range from hinge problems and order volumes to price. The latest report comes from the Taiwanese trade press and is based on sources within the supply chain. It describes a device that is not yet technically complete – while the contract manufacturer is simultaneously making the final adjustments for mass production.

Hinge and display as bottlenecks

According to the report, the technical testing phase caused a delay of one to two months. The main bottlenecks are considered to be the hinge design and the durability testing of the foldable screen – these two components are generally subjected to the greatest stress in folding devices and determine their lifespan.

At the same time, Foxconn is reportedly already working on the final adjustments for mass production. These two things are not mutually exclusive: Fine-tuning of the production lines can continue while individual tests are still ongoing. This is precisely why the exact market launch date remains uncertain.

Foxconn is leading the project alone

Apple is said to have entrusted Foxconn with the entire project – from the introduction of the new product to mass production. The manufacturer's experience with precision structural components and its ability to manage large production volumes were reportedly decisive factors.

One voice from the industry goes even further: Foxconn is the only Apple partner with a realistic prospect of reaching the expected production volume. The company is currently manufacturing on several fronts simultaneously anyway, as the iPhone 18 Pro has also entered mass production at the same time.

Conflicting signals within two weeks

It's striking how much this report deviates from recent accounts. At the beginning of July, it was stated that mass production was proceeding without any expected delays, and shortly before that, Apple had increased its order to around ten million units – a move that was attributed at the time to resolved issues with the hinge and circuit board. Test production had already begun in April.

Both accounts originate from the same supply chain but reach opposing conclusions. Reading only one of them will give a distorted picture. The realistic scenario is that different suppliers are at different stages of production, with some tests still underway while other parts of the manufacturing process are already well underway. For a device Apple is producing in this form factor for the first time, late adjustments would hardly be surprising.

What to expect from the foldable iPhone

The report doesn't change the expectation of a September launch: The iPhone Ultra is expected to be unveiled alongside the iPhone 18 Pro models. A foldable, book-style device is anticipated, featuring an inner screen of approximately 7.7 to 7.8 inches, an outer display of 5.5 inches, and a thickness of about 4.5 millimeters when folded.

Rumors suggest a starting price of over $2,000. In Germany, Austria, and Switzerland, the price tag is likely to be even higher, as US prices exclude sales tax, while prices in these countries already include VAT. All of this information is based on reports from the supply chain and remains unconfirmed until the official launch.

The release date for the iPhone Ultra remains an open question

The technical specifications of the foldable iPhone have solidified over the months, but the timeline remains fluid. There could well be some time between a September unveiling and the actual sales launch – a pattern Apple has used in the past with particularly complex devices. (Image: Shutterstock / Parilov)