Foldable phones come with big challenges, especially in hinge design. When phone brand OPPO set out to design their Find N5 model, the goal was ambitious: To create one of the slimmest, most durable foldable phones without compromising strength. Here’s how we at BLT helped them.
A key issue in the design process of the Find N5 was screen creasing. This is caused by an insufficient bending radius when the phone folds and unfolds repeatedly. Durability was another concern, as most conventional metal hinges struggle to survive 200,000 folding cycles without deforming.
Weight was also an issue. In many foldable models, the hinge alone accounts for over 10 percent of the phone’s total weight. This makes it difficult to achieve a truly lightweight design. Then there is reliability. Dust intrusion and mechanical wear are also common hinge failures, especially in high end devices where users expect smooth performance over years of use.
To solve these issues, OPPO needed to redesign its hinge from the ground up using stronger materials and more advanced manufacturing methods. That is where BLT’s metal AM and proprietary metal powders came into play.
The ideal material for a stronger, lighter hinge
To help OPPO achieve its vision for the Find N5, BLT applied aerospace grade titanium 3D printing to the phone’s hinge system. Titanium offered an ideal combination of strength, lightness and durability, while metal AM allowed for precise structural optimization, impossible to achieve with traditional manufacturing.
Through extensive testing and refinements, the BLT team successfully reduced the hinge thickness from 0.3 mm to just 0.15 mm. That is an incredible 50 percent reduction, making the hinge much slimmer while maintaining rigidity and strength. The new design also resulted in a 120 percent increase in structural strength, making the hinge far more resistant to mechanical wear. Screen deformation was also reduced, thanks to a 36 percent boost in hinge rigidity.
Durability was another critical factor. The new hinge design was tested for 100,000 folding cycles under extreme temperature conditions, ranging from -20 °C to 50 °C, ensuring that it could withstand real world use without failure. The Find N5 boasts two TÜV Rheinland certifications.
Perhaps most impressive was the efficiency of production. Thanks to multi laser AM technology, BLT was able to produce 300 hinges in just 25 hours, a pace that would have been very difficult to achieve using conventional methods.
Precision engineering – the Skyfold hinge
BLT’s role in this project went beyond material selection. The company also played a crucial part in optimizing the hinge structure for lightweight durability.
One of the most complex parts of the hinge is the wing plate, which shapes the droplet like bending radius when the phone is folded. This component supports the smooth unfolding of the flexible screen while reducing stress on the panel, helping to prevent visible creases over time.
Another key part is the outer rotating shaft middle frame, which plays a critical role in absorbing energy from accidental drops or impacts. This enhancement not only improves long term reliability. It also contributes to the phone’s overall structural integrity.
By leveraging metal AM’s design flexibility, BLT helped OPPO engineer a hinge that is thinner, stronger and longer lasting. Simply put – a new standard for foldable phone technology.
The continuous evolution of foldable phones
The pursuit of compact, functional mobile devices is not new. In 1989, Motorola introduced the StarTAC, the first flip phone, which popularized the idea of a folding design for portability. In 2004, the RAZR V3 refined the concept, becoming an iconic device known for its slim profile.
Fast forward to today and foldable screens are bringing back the clamshell concept but with advanced display technology and larger, more immersive screens. OPPO, Samsung and Huawei are among the manufacturers leading this shift, pushing hinge technology to new limits.
Taking center stage of this innovation pace is precision engineering and materials science, exactly where metal AM excels.
BLT taking lead in next-gen consumer electronics
BLT, Bright Laser Technologies, is at the forefront of metal additive manufacturing. We work across industries from aerospace and medical to consumer electronics.
By applying aerospace-grade production standards to 3C products, we help companies develop lighter, stronger and more efficient designs. From foldable phone hinges to wearables and precision components, metal AM is enabling high-performance consumer devices.
