iPhone Duo is already facing serious problems

The iPhone Duo was rumored to come out some time after the iPhone 18 Pro and iPhone 18 Pro Max even before their joint announcement at the beginning of September. The reason was always reported to be a mix of production challenges, which should’ve been resolved by now. However, a new report suggests that’s not the case and the first foldable iPhone is still facing difficulties, mere weeks ahead of launch.

iPhone Duo production problems continue even now

Apple hasn’t solved the production issues related to its first foldable smartphone, according to multiple reports (translated source) coming out of China. Due to the manufacturing challenges, the early output for the iPhone Duo, which is launching October 23, is expected to be limited.

One of the issues appears to be the low final assembly yields for the new device. Sources close to the Foxconn’s supply chain told to Chinese outlet Jiemian News that as of September 17, the yield rate was just over 60%. If nothing changes, it could take between six months and a full year for the production to reach a mature yield. 

It’s all about Apple’s quality requirements for the iPhone Duo

It appears that a big part of the difficulties are stemming from the quality requirements Apple has for the production of the iPhone Duo. One source said that suppliers are waiting for Apple to decide whether it will relax some of the quality requirements, which could accelerate production.

The issues don’t stem from a specific problem with a certain technology, but rather from Apple’s lack of experience in producing foldable phones. Foxconn is reportedly adjusting parts of the production line repeatedly, including equipment, assembly processes, and production parameters.

Outside the assembly issues, there were also yield problems, delivery delays, and design changes related to Samsung Display’s OLED panels and some components used for the hinge of the iPhone Duo. These delays are another part of the reason the assembler had less time to fine-tune the production line and speed up manufacturing.

The hinge has reportedly caused particular headaches for Apple. The company has reportedly tested Liquid Metal for some of its parts, but then reconsidered its whole approach ahead of mass production. Eventually, the hinge was announced to contain over 100 components, including a 3D-printed cover.

These challenges are the main reason for the delayed launch of the iPhone Duo, which people online think will enjoy very high demand. Users on Reddit have been speculating whether the reportedly mild interest in the iPhone 18 Pro was because of the foldable or not, but many say they expect pre-orders to be a “bloodbath.”

Apple needs to make a choice

Another report (translated source) coming out of China claims that one of Apple’s contractors has given it a difficult choice. The company needs to choose to prioritize yield or increased output, which are apparently mutually exclusive.

Apparently, the production line could be run harder, leading to more units of the iPhone Duo that can go on sale, but that would lead to more defective units and higher scrap costs. The other option is lower input, with fewer defects, and more manageable costs.

Apple is not alone in this type of issue, with Samsung also facing manufacturing problems with its own passport-style foldable. Apparently, the demand for the Galaxy Z Fold 8 was so high that the Korean company faced a shortage of a specific display chip. While this doesn’t seem to have affected supply, the company had to redirect inventory from future products to its current hit.

Patience is a virtue for a reason

I don’t plan to buy an iPhone Duo mostly because of its price, but even if I were to get one, I’d be prepared to wait a while. Just like the iPhone X, I expect this brand-new type of iPhone to experience delays, and I’m not the type of person to fight for a pre-order.

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