According to renowned analyst Ming-Chi Kuo, the iPhone Fold’s unique hinge structure could lower manufacturing costs by $20 to $40 per unit compared to earlier market estimates.

Kuo revealed that once mass production begins, the average cost of producing a hinge for the iPhone Fold will range from $70 to $80 per unit, far below the current estimate of $100 to $120. This could help Apple save tens of millions of dollars when producing at scale.

The hinge: Apple’s ‘secret weapon’ for the iPhone Fold

The ability to fold is the standout feature of the iPhone Fold, and the hinge is the key to its durability, smooth operation, and user experience.

A flexible display demands a robust hinge mechanism - one that operates smoothly without leaving creases or putting excessive pressure on the screen panel.

To achieve this, Apple has invested heavily in hinge research, widely considered the most complex and expensive component in foldable smartphone design.

However, Kuo believes improvements in manufacturing techniques may allow Apple to manage costs while still delivering exceptional quality.

The hinge production will be handled by two major Apple supply chain partners: Foxconn, Apple’s long-standing assembly partner, and Shin Zu Shing, a specialist in precision mechanical components.

Together, these firms will manage around 65% of the total hinge orders, while the rest will be fulfilled by Amphenol, a U.S.-based supplier.

If the iPhone Fold proves commercially successful, Apple may expand production to third-party manufacturers. According to rumors, Luxshare - which currently assembles AirPods and several iPhone models - may join the project after 2027.

This added competition is expected to drive production costs even lower, further maximizing Apple’s profit margins.

A familiar design with new materials

Previous leaks have suggested the iPhone Fold may resemble two iPhone Air devices joined by a central hinge.

To keep the device thin, light, and durable, Apple is expected to use a titanium-aluminum alloy frame, similar to what’s found on the iPhone 15 Pro.

While Kuo had earlier predicted the use of stainless steel and liquid metal, he now believes that combination would make the device too heavy, negatively impacting ergonomics and user experience.

Though the supply chain and technical roadmap are gradually becoming clearer, the future of the iPhone Fold remains uncertain.

Since 2019, speculation has swirled that Apple’s first foldable phone is “just a year away,” yet it has yet to materialize.

At this stage, Kuo has not disclosed a specific launch date or project timeline. However, the completion of hinge design and the preparation of manufacturing partners suggest the iPhone Fold is closer than ever to becoming reality.

With rivals like Samsung, Huawei, Oppo, and Google having launched multiple generations of foldable phones, Apple can no longer afford to sit out the competition.

Still, staying true to its “better late but perfected” philosophy, Apple appears to be waiting until materials and mechanical technologies mature enough to deliver a top-tier user experience.

Now that one of the most expensive components - the hinge - is becoming more affordable, the iPhone Fold may finally be economically viable.

If everything goes according to plan, this could be the final piece Apple needs to officially enter the foldable phone era.

Hai Phong