Apple iPhone Fold likely to launch with a 3D printed hinge

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• Apple may 3D print iPhone Fold hinge to cut screen crease
• iPhone Fold expected to launch in late 2026 with dual-layer glass
• Apple readies mass production to rival Samsung foldables

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Leaks and rumours about the foldable iPhone has been surfacing for years. And, this year, Apple is finally expected to enter the foldable smartphone segment with the iPhone Fold, and new leaks suggest the company may adopt a 3D printed hinge design. The move is aimed at reducing the crease that typically appears on foldable displays. The device is rumoured to launch in late 2026, potentially alongside the iPhone 18 Pro series.

According to a tip shared on Weibo, Apple could use 3D printed materials in the hinge mechanism of the iPhone Fold. This approach is expected to help minimise the visibility of the crease on the inner display. Foldable smartphones from multiple brands have faced challenges related to screen creases, and hinge design plays a key role in addressing this issue.

Apple is not new to using 3D printing in its products. The company already uses 3D printed components in devices such as Apple Watch cases and internal parts like USB Type-C ports in recent iPhone models. Extending this technology to the hinge could help improve structural precision and consistency.

Display design and durability improvements

The iPhone Fold is also tipped to feature a dual-layer glass setup. Reports suggest the use of UTG (ultra-thin glass) and UFG layers, where the display sits between two thin sheets of glass. This design could prevent the display from directly interacting with the hinge during folding, reducing stress on the panel.

Such a setup may contribute to improved durability and reduce long-term wear on the foldable screen. Apple has reportedly been working on reducing crease-related issues for several years as part of its foldable development efforts.

The foldable iPhone is expected to arrive in late 2026. Apple is also tipped to increase orders for foldable display panels from Samsung Display, with estimates suggesting up to 20 million units. This indicates that the company is preparing for large-scale production.

The iPhone Fold, which may also be marketed as the iPhone Ultra, is expected to compete with existing foldable smartphones, particularly Samsung’s Galaxy Z Fold lineup.