The iPhone Air is Apple’s thinnest iPhone yet at just 5.6mm, and naturally iFixit wasted no time tearing it apart. What they found inside wasn’t just clever engineering, but also a glimpse at how Apple may be testing the future of iPhone design.
A 3D-Printed USB-C Port in an iPhone?
One of the most surprising discoveries is the USB-C port. Instead of the standard manufacturing Apple usually relies on, iFixit says the company 3D-printed the part using a titanium alloy.
That makes it structurally strong enough to handle daily wear but not quite as scratch-resistant as the rest of the frame. The port is glued in but modular, which means it can be replaced if needed and is a good sign for repairability.
How Apple Made It So Thin
To squeeze everything into the ultra-slim body, Apple partially tucked the logic board inside the camera bump. This design allowed room for a metal-encased 12.26Wh battery, which interestingly is the same battery found inside the MagSafe Battery pack for the iPhone Air.
Suggested: iPhone Air’s Battery Life Might Be Better Than You Think
Despite its slim build, the Air isn’t too fragile. Bend tests show the titanium frame holds up well, even if it does have weak points where Apple added plastic gaps for cellular performance.
Repairability Gets a Boost
Another welcome surprise? The iPhone Air is easier to repair than many expected. iFixit gave it a provisional score of 7/10 thanks to design choices like clip-in display and back glass panels, plus a battery that can be loosened with a low-voltage current.
Apple also seems more open to self-repair by offering spare parts and reducing software locks.
This teardown proves that Apple didn’t just make the iPhone thinner, it’s also quietly experimenting with new materials and methods. If 3D-printed parts make it into more models, we might just be looking at the future of iPhone manufacturing.
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