Teardown reveals three theories for why iPhone Duo's screens keep cracking

iFixit recently dismantled the iPhone Duo to assess its repairability and uncover the reasons behind numerous units returning with broken screens shortly after launch. Although the exact cause of the damage remains undetermined, the team has presented three plausible hypotheses based on CT scans, 3D modeling, and breakage patterns.

The most likely explanation for the breakages is a malfunctioning central support bar inside the hinge. This bar is meant to retract when the phone closes, but it seems to be failing to retract far enough, causing the curved section of the inner display to press against it. This repeated stress over time leads to a crack at that specific location.

Another potential culprit is the curved rails that guide the hinge's movement. The team discovered that the rails are designed to rise above surrounding components during folding, but may collide with the screen if misaligned, leading to cracks and other damage.

The third hypothesis suggests that the issue may be a design flaw rather than a single malfunctioning component. Internal structural edges and components converge precisely at the transition zone between the cable connector and the central hinge support. This concentration of stress on the display, particularly around this area, could cause catastrophic damage due to the repeated opening and closing of the device.

The thin display layers, barely a few microns thick, are unable to withstand the stress, resulting in screen failure. Even though the iPhone Duo boasts an IP68 rating, fine dust particles still manage to infiltrate the hinge mechanism, causing a disconcerting crunching sound that may indicate potential damage to both the hinge and the screen.

Despite these issues, the iPhone Duo is one of the most repairable foldables on the market, earning iFixit a provisional repairability score of 5 out of 10.