The iPhone Duo, Apple’s first foldable smartphone, is reportedly facing significant production difficulties just weeks ahead of its release. Set to launch on 23 October, the device could arrive with limited early availability as manufacturing challenges persist.
The foldable had long been expected to arrive some time after the iPhone 18 Pro and iPhone 18 Pro Max, which were jointly announced at the beginning of September. Production issues were always cited as the reason for the staggered timing, yet those problems appear to remain unresolved.
iPhone Duo production problems continue
Multiple reports from China indicate that Apple has yet to overcome the manufacturing hurdles tied to its debut foldable. As a result, initial output for the iPhone Duo is expected to be constrained at launch.
A key issue is the low final assembly yield for the new device. As of 17 September, the yield rate stood at just over 60%. If conditions do not improve, it could take between six months and a full year for production to reach a mature yield.
Apple’s quality requirements at the heart of the delays
Much of the difficulty appears to stem from the strict quality requirements Apple has set for the device. Suppliers are reportedly waiting to see whether the company will relax some of these standards, a move that could accelerate production.
The problems are not linked to a single technology but rather to Apple’s limited experience in producing foldable phones. Foxconn is said to be repeatedly adjusting parts of its production line, including equipment, assembly processes, and production parameters.
Beyond assembly, there have also been yield problems, delivery delays, and design changes involving Samsung Display’s OLED panels and certain components used in the hinge of the device. These setbacks left the assembler with less time to refine the production line and increase manufacturing speed.
The hinge has proven especially troublesome. Apple reportedly tested Liquid Metal for some of its parts before reconsidering its entire approach ahead of mass production. The final hinge was announced to contain more than 100 components, including a 3D-printed cover.
These combined challenges are the primary reason behind the delayed launch of the iPhone Duo, a device widely expected to attract strong demand.
Apple faces a difficult choice
A further report from China claims that one of Apple’s contractors has presented the company with a difficult decision. Apple must choose between prioritising yield or increasing output, options that are reportedly mutually exclusive.
Running the production line harder would produce more units of the device available for sale, but it would also lead to a greater number of defective units and higher scrap costs. As of 17 September, the yield rate for the foldable stood at just over 60%.
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Image: phonearena.com
