Every foldable phone currently on the market carries the same visible compromise: a crease running down the center of the internal display. You notice it immediately when light catches the fold at certain angles. Samsung has iterated through six generations of the Galaxy Z Fold line, refining hinge mechanisms, adjusting UTG formulations (the ultrathin glass layers that cover foldable displays), and experimenting with display stack configurations. The crease persists. Google’s Pixel Fold carries it. Motorola’s razr carries it. The crease has become an accepted industry tax, a visual and tactile reminder that folding glass remains an unsolved materials engineering challenge.
What we know: Jon Prosser leaked renders on December 24, 2025 depicting a book style foldable iPhone alongside the iPhone 18 series, targeted for Fall 2026, with reported pricing between $2,000 and $2,500. What remains unverified: The central claim of zero visible crease, which cannot be confirmed until production hardware is tested.
Recent leaks from Prosser suggest Apple intends to eliminate this compromise entirely. The renders depict a book style foldable iPhone expected alongside the iPhone 18 series in Fall 2026. Zero visible crease on the internal display. If accurate, this represents not an incremental refinement but a fundamental breakthrough in foldable display architecture.
The Engineering Challenge Behind the Crease
Understanding why the crease exists requires examining the layer stack of a flexible OLED panel, and the answer lies in material behavior rather than design oversight. Traditional rigid OLEDs use glass substrates that provide structural stability and optical clarity, creating a surface that feels seamless under the finger and reflects light uniformly across its entire area. Foldable displays replace this glass with plastic substrates, typically polyimide (PI), which can flex repeatedly without fracturing but responds to mechanical stress in ways that accumulate over time, and the plastic remembers each fold. Each fold leaves a trace, invisible at first, then gradually visible as the substrate fatigues along the bend axis. Samsung’s UTG approach adds a thin glass layer for improved feel and scratch resistance, but that glass develops micro-fractures along the bend radius that compound the problem over time.
When a foldable display bends along its hinge axis, the material on the outer curve stretches while the material on the inner curve compresses. This differential stress accumulates at the fold line, creating permanent deformation in the plastic substrate. The encapsulation layers, touch sensor films, and polarizer sheets all respond differently to this stress, compounding the visible crease into something you can both see and feel. If you run your fingertip slowly across the center of any current foldable, that slight bump tells the story of mechanical compromise.
The bend radius matters enormously, because tighter radii create more stress concentration while wider radii reduce stress but increase device thickness when closed. Every foldable manufacturer has navigated this tradeoff differently, but none has eliminated the fundamental physics that creates the crease.
Apple’s Alleged Solution: Metal Dispersion and Liquid Metal Hinges
Prosser’s leak describes two key engineering innovations, and the approach is clever in its simplicity. The first involves a metal plate positioned beneath the display that disperses bending pressure across a wider area rather than concentrating it along a single axis.
The dispersion plate concept addresses the stress concentration problem directly, representing a fundamental rethinking of how force should travel through a folding display stack. Rather than allowing the display to experience maximum strain along a narrow fold line, the metal plate would distribute that mechanical load across a broader zone. This approach resembles structural engineering principles used in suspension bridges, where forces spread across multiple support points rather than concentrated at single anchors. The geometry of such a plate would need to be precisely calculated, balancing flexibility with rigidity, weight with durability. Whether Apple has developed a plate configuration that achieves this without adding prohibitive thickness or weight remains the critical engineering question.
The second innovation involves a liquid metal hinge mechanism, likely referencing Apple’s existing work with Liquidmetal, a zirconium-based amorphous alloy the company has explored in various applications since acquiring licensing rights in August 2010. Amorphous metal alloys can be molded into complex geometries with extremely tight tolerances, potentially enabling hinge designs that control the bend profile more precisely than machined components allow. The material’s natural lubricity and resistance to fatigue could improve long-term reliability, addressing the mechanical feel of traditional hinges with something that operates more fluidly.
Form Factor Analysis: What the Dimensions Reveal
The leaked dimensions reveal Apple’s engineering priorities with unusual clarity. The device measures 9mm thick when closed, splitting to approximately 4.5mm per half, making the unfolded thickness sit at just 4.5mm. The iPhone 15 Pro measures 8.25mm. Apple’s foldable, closed, would be only marginally thicker than current flagship iPhones while delivering a 7.8-inch internal display.
These dimensions suggest aggressive component miniaturization and careful thermal management. Apple reportedly uses its second generation modem developed internally (C2) and high-density battery cells enabled by a slimmer display driver. The shift from Face ID to Touch ID in the power button represents another space-saving decision, eliminating the TrueDepth camera array that occupies significant volume in current iPhone designs.
The Production Reality Gap
Renders exist in a frictionless conceptual space. Every surface appears seamless. Every material performs to theoretical maximum.
Production hardware operates under different constraints, and the question of whether Apple has genuinely solved the crease problem cannot be answered until someone folds and unfolds a production unit under varied lighting conditions, at different temperatures, after thousands of cycles. The crease typically worsens with age as wear accumulates. A render cannot show what happens at month six. Previous reports suggested Apple figured out how to minimize the crease; Prosser’s leak suggests it might be eliminated entirely. These statements describe meaningfully different engineering achievements: minimization implies a visible crease less pronounced than competitors, while elimination implies none at all.
Material Considerations and Manufacturing Scale
Assuming Apple has developed a crease-free folding mechanism, the question becomes whether it can be manufactured at iPhone scale. Apple ships iPhones at a scale that dwarfs the entire foldable category. Every component must be producible in quantities that dwarf what Samsung delivers for its foldable line, where foldable shipments represent a small fraction of overall smartphone volumes.
The dispersion plate, if it uses exotic geometries or materials, could present manufacturing bottlenecks that slow initial production to a trickle. Liquid metal components require specialized casting and forming processes that Apple has used only in limited applications: SIM tray ejector tools, Apple Watch Series 9 buttons. Scaling to display-size components at flagship volumes would require substantial production infrastructure investment. Display panel supply presents another constraint. Samsung Display currently dominates flexible OLED production, and Apple has worked with LG Display and BOE to diversify its supplier base, but building capacity for an entirely new flexible panel format would require years of development and billions in capital expenditure from panel makers. The supply chain alone could determine whether this device ships in millions or hundreds of thousands.
Pricing and Market Position
The expected price tells its own story. Prosser suggests pricing between $2,000 and $2,500, though he hedges on the exact figure.
This range positions the foldable iPhone above the Galaxy Z Fold 6, which starts at $1,899, while falling short of the most extreme luxury phone territory. For Apple, this represents uncharted pricing for a mainstream product line. The iPhone Air’s reported sales struggles, if accurate, suggest limits to what consumers will pay for form factor innovation alone. The foldable iPhone will test whether Apple’s brand premium extends to a new device category or whether the foldable market itself has a price ceiling that even Apple cannot exceed.
Color options limited to black and white reflect Apple’s tendency to constrain initial product launches, signaling a cautious market entry rather than a mass market push. Premium positioning with limited variants allows Apple to manage supply constraints while testing demand at the high end of the price spectrum.
The strategic bet is clear, and Apple appears confident enough buyers exist at this price point to justify years of R&D and tooling investment, even if the initial addressable market remains narrow.
The Broader Display Technology Implications
If Apple has genuinely solved the crease problem, the implications ripple far beyond smartphones, touching every device category that could benefit from flexible displays. Foldable tablets, laptops with folding displays, and rollable screen formats all face similar material constraints, and a breakthrough in stress distribution or substrate engineering would have applications across the entire flexible display industry. The solution, whatever form it takes, would likely be protected by extensive patent filings. This could create licensing opportunities or, more likely given Apple’s historical tendencies, a proprietary advantage that competitors cannot easily replicate.
Samsung has built its foldable ecosystem partly on component sales. An Apple breakthrough using internally developed technology would disrupt that supply chain dynamic. Other manufacturers would need to license Apple’s approach or develop their own solutions from scratch.
The timing of a Fall 2026 launch, if accurate, gives Apple nearly two years to refine manufacturing, build component inventory, and develop the software experiences that justify a foldable form factor. iOS adaptations for larger internal displays, multitasking paradigms, and app developer frameworks would all require substantial engineering investment beyond the hardware itself. The display breakthrough means nothing without software that makes the larger screen worth having.
What Remains Unknown
The crease claim stands as the most important detail and the least verifiable. Prosser has accurately predicted some Apple announcements and missed on others. His track record provides some credibility but not certainty. Until production hardware reaches independent reviewers, the fundamental promise of Apple’s foldable remains speculative.
The legal context adds intrigue, and the question of source reliability becomes harder to untangle when litigation enters the picture. Apple sued Prosser in July 2025 for leaking iOS 26 and Liquid Glass design details, and his response appears to be leaking even more. Whether this reflects confidence in his sources or defiance toward Apple’s legal pressure is difficult to assess from outside. For the foldable display industry, the claim itself matters regardless of accuracy: if Apple believes a crease-free folding display is achievable, the engineering resources the company can deploy dwarf what any competitor has invested. Even if the initial implementation falls short of the leaked renders’ promise, Apple’s entry would accelerate development across the entire foldable ecosystem. The question that defines this product will not be answered by renders or leaks. It will be answered by light catching, or not catching, a fold line at certain angles. By fingertips feeling, or not feeling, a ridge when swiping across the center of a 7.8-inch display. Fall 2026 will provide the answer.
Specifications
The leaked specifications paint a picture of aggressive engineering tradeoffs. Apple appears to have prioritized thinness and internal display size over external screen real estate, betting that users will spend most of their time with the device unfolded. The choice of Touch ID over Face ID represents a meaningful departure from Apple’s biometric strategy of the past decade, suggesting the engineering constraints of fitting a foldable mechanism left no room for the TrueDepth camera array.
Specification
Details
External Display
5.5 inches
Internal Display
7.8 inches
Closed Thickness
9mm
Unfolded Thickness
4.5mm
Hinge Type
Liquid metal mechanism with dispersion plate (reported)
Biometrics
Touch ID (power button)
Modem
Apple C2, reported as second generation internal modem
Colors
Black, White
Expected Price
$2,000 to $2,500
Expected Launch
Fall 2026
These numbers remain unverified until production hardware surfaces. Prosser’s track record includes both accurate predictions and notable misses, so treating any single specification as confirmed would be premature. The fall 2026 timeline, if accurate, gives Apple roughly eighteen months from now to finalize these details.
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