iPhone Ultra launch back on track after Apple fixes critical foldable issue: Report

Apple's first foldable iPhone is reportedly back on track for its planned September launch after overcoming a key hurdle related to its hinge.

According to a new report by The Elec, Apple has completed the final verification stage for the iPhone Ultra and will now begin mass production of the device by the end of July.

The report, citing Apple supply chain officials in Korea and Taiwan, notes that the company has finalised the key specifications for the iPhone Ultra, including the display, case, and mechanical components, and is now entering the mass production phase.

Apple's long-time manufacturing partner, Foxconn, is reportedly expected to begin mass-producing the foldable iPhone by the end of next month.

The iPhone Ultra had already completed trial production in April, during which manufacturers validated the design, assembly process, and production quality before full-scale manufacturing began.

iPhone Ultra hinge issues solved

The report noted that Apple had encountered problems with the foldable iPhone's hinge during development. Reportedly, after millions of durability tests, engineers found some noise in the hinge on the iPhone Ultra.

“In some assembly processes, tolerances were larger than expected, resulting in a somewhat higher defect rate.” an unnamed industry insider from Taiwan told The Elec.

However, the same source told The Elec that most of these issues have now been resolved, allowing Apple to move ahead with mass production.

Notably, the hinge is a very important component in a foldable smartphone and is primarily responsible for opening and closing the device.

Apple is reportedly sourcing hinge modules from Taiwan's Shinjuxing and US-based Amphenol. Both companies are said to be using 3D printing technology to manufacture the parts.

Meanwhile, Samsung Display is reportedly supplying the foldable OLED panels and has received Apple's initial approval for production volumes from its Vietnam facility.

The report also once again confirmed the long-standing rumour that Apple will not be launching a standard iPhone 18 model this year and will instead focus on launching the iPhone 18 Pro, iPhone 18 Pro Max, and iPhone Ultra.

Instead, the standard iPhone is expected to be moved to a launch window next spring.

While the report says Apple remains on track for a September unveiling, it does note that the iPhone Ultra's sales date could be later than that of the normal iPhones if Apple identifies any last-minute quality issues.

iPhone Ultra specs: