The hinge for Apple’s new foldable phone was built with AI

Apple used its Surprise and Shine event to unveil the Duo, the company’s first foray into foldable phones. The product enters a market where foldable devices have generated consumer interest but frequently suffer accelerated wear because their moving form factor is subject to more stress than conventional smartphones.

According to Apple’s chief hardware officer Johny Srouji, the Duo’s hinge was developed with a combination of AI and precision additive manufacturing. Apple says AI algorithms are used during production to pair each hinge with the best-fitting housing for alignment. A confocal laser then scans the surface topology of each unit, and the company applies up to 25 micro layers of a custom photopolymer via 3D printing to remove residual waviness.

Beyond the hinge, Apple says it added a custom nano-texture finish intended to cut glare and reflections, and implemented a multilayer lamination approach aimed at improving overall durability. These measures are presented as targeted responses to the common weaknesses of foldable designs, which typically experience more mechanical wear than traditional phones.

Apple’s description outlines a manufacturing approach that combines AI-driven matching and micro-scale 3D printing with surface and lamination treatments. While the company frames these steps as protections against the usual degradation of foldables, how well the Duo holds up over time will only be proven once devices are in extended real-world use.