Apple’s Thinnest iPhone Still Stands Up to Repairs: iPhone Air Teardown Overview Apple’s new iPhone Air, at just 6.5 mm thin, is the thinnest iPhone ever designed. Despite concerns that a thinner phone might sacrifice durability and repairability, the iPhone Air demonstrates clever engineering that enables easier repairs and maintains durability. --- Key Highlights Clever Use of Internal Space Apple restructured the internal layout by placing the logic board above the battery rather than alongside it. The phone’s center consists mostly of a large battery with a frame around it. This design yields a flatter disassembly tree, reducing the number of parts blocking others and making repairs faster and less risky. The layout also reduces stress on the logic board during pocket flexing, addressing past “bendgate” issues. Battery Design and Replacement The battery is smaller than in recent iPhones (12.26 Wh vs. 13 Pro’s 11.97 Wh), raising some battery life questions, but Apple’s efficiency possibly compensates. Battery is encased in metal, increasing bend resistance and safety during replacements. Uses electrically debonding adhesive strips, allowing the battery to come out easily with electrical stimulation, reducing risk compared to traditional prying. Battery comprises about 28% of the phone’s weight. Compatible with Apple’s MagSafe battery pack cell, allowing interchangeable battery use. Modular USB-C Port The charging port is a modular component, moderately easy to replace but involves delicate flex cables and screws. Apple does not currently offer USB-C port repairs in-house or sell official replacements. iFixit plans to stock parts for DIY repairs soon. The port housing is 3D-printed titanium, a novel manufacturing approach reducing material use by 33% and yielding a lightweight but strong structure. Microscopic imaging revealed unique bubble-like titanium structures likely from a specialized 3D-printing and post-processing technique. Build Quality and Durability Titanium is used for the frame, providing strong support. Bend testing shows the phone is most vulnerable at plastic antenna cutouts on the top and bottom of the frame. The reinforced center section is sturdier, preventing flex failures in typical use. Early durability tests indicate no significant flexibility issues despite the slim profile. --- Repairability Score: 7/10 The iPhone Air balances ultra-thin design with practical repairability features. Dual-entry battery access, modular parts, and clipped/screwed screen and back glass help simplify repairs. Apple provides day-one repair manuals. Awaiting final confirmation on parts availability; Apple’s recent history suggests promising support. Comparisons: Slightly thinner than Samsung Galaxy S25 Edge (5.8 mm). Incorporates improved internal layout to ease repairs and minimize damage risk. --- Community Feedback Comments highlight enthusiasm for Apple adopting repair-friendly features like electrically debonding adhesives. Recognition of innovative technology packed in a compact design. Appreciation for continued industry innovation balancing slimness with repair accessibility. --- Additional Notes iFixit is collaborating with JerryRigEverything on a toolkit designed for repairs and durability testing on the go. Further teardowns of Apple’s 2025 lineup are upcoming. Related guides available, such as cleaning electronic device ports, to assist with maintenance. --- Summary The iPhone Air sets a new standard for slim smartphones by integrating an innovative internal design that promotes repair accessibility without sacrificing durability. Its use of modular parts, battery innovation, and lightweight titanium frame allow it to earn a provisional repairability score of 7/10. Apple shows that ultra-thin devices can still be user-friendly for repairs, marking a positive development in smartphone design.