Apple’s long-rumoured foldable iPhone appears to be edging closer to reality, with leaks suggesting the so-called ‘iPhone Ultra’ remains on track for a September 2026 launch – despite major engineering hurdles behind the scenes.

Multiple reports over the past week claim Apple has entered trial production for its first foldable handset, with Foxconn reportedly preparing for mass production as early as July. The device is tipped to launch alongside the iPhone 18 Pro range later this year.

According to prominent Weibo leaker Instant Digital, Apple has achieved one of the foldable industry’s biggest challenges: a virtually crease-free display. Early testing reportedly shows the screen can maintain a “visually crease-free state” even after prolonged use.

That would mark a significant breakthrough in the foldable smartphone market, where visible display creases and hinge durability have remained persistent issues for Samsung, Google and other rivals.

How Apple's folding iPhone will crack the crease problem | Cult of Mac

However, Apple’s foldable ambitions are reportedly being slowed by reliability concerns surrounding the hinge mechanism itself. Sources claim the hinge is failing to consistently meet Apple’s strict durability standards under repeated folding and unfolding tests.

The company is said to be using Liquid Metal, also known as metallic glass, in the hinge structure, a material believed to offer greater resistance to bending and wear than titanium alloys. Apple has reportedly explored the material for years but has only previously used it in smaller components such as SIM ejector pins.

Despite the setbacks, leaks suggest Apple still intends to unveil the foldable device in September, provided engineers can resolve the hinge issues in time for full-scale production.

The foldable iPhone Ultra is expected to feature a 7.8-inch inner OLED display, a 5.5-inch outer screen, Apple’s next-generation A20 Pro chip and a titanium-aluminium chassis measuring just 4.5mm thick when unfolded.

Other rumoured features include a Touch ID-enabled power button, dual rear cameras and a starting price around A$3,100, making it Apple’s most premium iPhone to date.