The manufacturing process goes beyond producing identical hinges and placing them into identical housings. Apple instead uses algorithms to determine which housing is the best match for each individual hinge.
“During manufacturing, we use AI algorithms to precisely match each individual hinge with its best-fit housing to ensure perfect alignment, and a confocal laser progressively scans the topology of every single unit and 3D prints up to 25 micro layers of a custom photopolymer to eliminate residual waviness,” Apple hardware chief Johny Srouji said.
That makes AI part of the Duo’s production process rather than a feature customers directly interact with. After the initial pairing, Apple scans each hinge and can add as many as 25 thin photopolymer layers to compensate for remaining surface variation.
Apple has built the rest of the folding display around a similar focus on materials and construction. The company says the inner screen uses high-strength glass, custom adhesives and multiple laminated layers intended to handle the stresses created when the display bends.
The phone also uses a custom polymer cover that Apple says is up to 40% stiffer than other materials used in the industry. A nano-textured finish is designed to reduce glare and reflections, while the hinge cover is also produced using 3D printing.
Taken together, Apple is relying on several manufacturing techniques rather than pointing to a single component as the solution to foldable durability. The hinge calibration is one part of that approach, alongside the display materials, adhesives, coatings and lamination.
Whether those measures translate into better long-term durability will only become clear after the device sees sustained everyday use. Repeated folding places stresses on a phone that conventional designs do not experience, making the hinge and flexible display two of the Duo’s most consequential components.
Preorders for the iPhone Duo begin October 16, with availability starting October 23.
This analysis is based on reporting from Superpower Daily.
Image courtesy of Apple.
This article was generated with AI assistance and reviewed for accuracy and quality.
