How We Redesigned the Pixel 9 Pro Fold and Made It Thinner

When it comes to foldable phones, innovation is constantly pushing the boundaries of what’s possible. The Pixel 9 Pro Fold represents the latest evolution in foldable smartphone technology, and one of the key challenges we set out to solve was making it thinner without compromising on performance or durability. The result? A foldable device that is sleeker, more powerful, and more user-friendly than ever before.

Here’s a look behind the scenes at how we redesigned the Pixel 9 Pro Fold and achieved a thinner, more refined form factor, all while enhancing its functionality.

The Quest for Thinness: Why It Matters

Foldable phones are inherently more complex than standard smartphones. With dual screens, intricate hinges, and advanced internals, they often end up feeling bulky in the hand or pocket. When we started designing the Pixel 9 Pro Fold, thinness wasn’t just a cosmetic goal; it was about improving the user experience. A thinner device is easier to hold, carry, and use with one hand. It also makes the foldable screen feel more seamless, giving users a more natural interaction when switching between folded and unfolded modes.

The challenge, however, was clear: how do we reduce the thickness without sacrificing battery life, camera quality, or the robustness of the hinge mechanism? To solve this, we had to rethink every component of the Pixel 9 Pro Fold.

1. Redesigning the Hinge Mechanism: The Heart of the Foldable

One of the most critical elements in any foldable phone is the hinge. It’s responsible for ensuring smooth transitions between folded and unfolded states while maintaining the phone's durability. With the Pixel 9 Pro Fold, we completely redesigned the hinge to be more compact and precise.

Our engineers developed a new ultra-slim hinge mechanism that uses fewer moving parts while maintaining the same level of durability and flexibility. This allowed us to shave off millimeters from the thickness of the phone. The new hinge also provides a tighter fold, reducing the gap between the two screens when the phone is closed. This not only contributes to a thinner profile but also protects the display from dust and debris.

2. Advances in Display Technology

The Pixel 9 Pro Fold’s signature feature is, of course, its foldable display. We partnered with leading display manufacturers to develop a next-generation flexible OLED that is not only thinner but also more durable. This new display panel uses ultra-thin glass (UTG) with improved scratch resistance, making it more resilient while keeping the device slim.

By moving to this advanced OLED technology, we were able to reduce the thickness of the display layers without compromising brightness, color accuracy, or touch sensitivity. The thinner display also allows for better heat dissipation, which in turn helps improve the overall performance and longevity of the device.

3. Battery Innovation: Bigger Power, Smaller Size

Reducing the size of the Pixel 9 Pro Fold didn’t mean we could reduce its battery capacity. Users expect long-lasting performance, especially with a foldable device powering two screens. To achieve a thinner design while maintaining battery life, we turned to new battery technology that is both more energy-dense and compact.

We incorporated a custom-designed dual-cell battery system that fits more efficiently into the thinner frame of the Pixel 9 Pro Fold. This system allows the battery to be distributed more evenly across the device, which not only helps with maintaining balance when holding the phone but also frees up space for other components. The result is a thinner device that still offers all-day battery life, even with heavy usage.

4. Streamlined Internal Components

To further slim down the Pixel 9 Pro Fold, we needed to optimize the arrangement of the phone’s internal components. We worked closely with our hardware teams to design a custom motherboard that consolidates key components into a smaller footprint.

By integrating the processor, memory, and storage in a more efficient way, we were able to save valuable space inside the device. We also used smaller, more efficient cooling solutions, which allowed us to maintain top-tier performance without the need for bulky heat dissipation systems.

Every millimeter counted in this redesign, and by streamlining these components, we were able to achieve a thinner profile without compromising the power and speed that users expect from the Pixel series.

5. Camera System: Powerful, Yet Compact

Foldable phones are notorious for having less space for high-end camera systems, but that wasn’t something we were willing to sacrifice. The Pixel 9 Pro Fold features our most advanced camera technology yet, and we had to find a way to fit it into the slimmer design.

We developed a new periscope lens system that allows for powerful optical zoom without the need for a large camera bump. This technology uses a series of mirrors to bend light inside the phone, allowing for longer focal lengths in a more compact space. Along with AI-powered computational photography, the Pixel 9 Pro Fold delivers stunning image quality without compromising on design.

6. Materials: Lighter, Stronger, and Thinner

To support the thinner design, we also made advancements in the materials used for the Pixel 9 Pro Fold’s chassis. We incorporated a lighter, aerospace-grade aluminum frame that is both durable and incredibly slim. This material not only reduced the overall thickness of the device but also made it lighter, improving the overall feel in the hand.

We also refined the back panel of the Pixel 9 Pro Fold, using a composite material that is stronger yet thinner than traditional glass. This allowed us to offer a more premium look and feel while ensuring the phone remains protected from drops and everyday wear and tear.

7. Software Optimization for a Foldable Experience

A thinner phone also means the software must be optimized to take full advantage of the hardware. The Pixel 9 Pro Fold runs a customized version of Android tailored specifically for foldable devices. By optimizing how apps run in both folded and unfolded states, we were able to ensure a seamless user experience that feels intuitive and fluid.

From split-screen multitasking to adaptive user interfaces, the software has been designed to make the most of the larger screen real estate while maintaining smooth performance. This level of optimization is crucial in ensuring that the Pixel 9 Pro Fold isn’t just thinner but also smarter and more responsive.

Thinner Without Compromise

The Pixel 9 Pro Fold is a testament to our commitment to pushing the boundaries of design and engineering. By redesigning the hinge, advancing display technology, optimizing internal components, and using cutting-edge materials, we were able to create a foldable phone that is thinner, lighter, and more powerful than ever before.

The result is a device that not only looks sleek but also delivers the full Pixel experience in a foldable form factor. The Pixel 9 Pro Fold is proof that thin doesn’t have to mean compromise—it can mean innovation.