Apple Designer on Why Curved Glass and Extruded Aluminum iPhone Designs Were Rejected

With court documents in the ongoing legal dispute between Apple and Samsung having yielded a remarkable number of design concepts and prototypes from the development of the iPhone and iPad, Network World has taken a look at testimony that explains why Apple rejected some of the ideas. The testimony comes from Doug Satzger, who spent 12 years in industrial design at Apple before moving on to Palm in early 2009 and then joining Intel earlier this year.

Most notably, Satzger reveals that Apple very much wanted to use a curved glass design for the iPhone, but cost considerations and technical hurdles forced Apple to change directions.

The technology in shaping the glass, the cost relative to shaping the glass at the time, and some of the design features of this specific shape were not liked. [...]

The technology at the time had a lot to do with it. The qualities of the glass at the time had a lot to do with it. These are models -- I'm trying to remember a time frame -- that were before gorilla glass and before a lot of the other factors.

curved glass iphone prototype
"0355" iPhone prototype with curved glass on front and back

Satzger also addressed Apple's ideas for an extruded aluminum design similar to that of the iPod mini, noting that the design was rejected for both comfort and technical reasons.

My recollection of it was that to get the extruded aluminum design that was applied to the iPod to work for the iPhone, there were too many added features to allow it to be comfortable and to work properly. [...]

If you put an iPod up to your ear, the sharp edges, because of the processes, aren't comfortable, and you can't get antennas to work properly in a fully enclosed metal jacket. So each one of those things needed to apply other features that started.

NewImage31
iPhone with silver iPod mini-like extruded aluminum design (Source: The Verge)

Related Forum: iPhone

Popular Stories

iOS 26

iOS 26.1 Coming Soon: New Features for Your iPhone and Release Date

Monday October 27, 2025 7:55 am PDT by
The upcoming iOS 26.1 update includes a handful of new features and changes for iPhones, including a toggle for changing the appearance of the Liquid Glass design, "slide to stop" for alarms in the Clock app, and more. Below, we outline key details about iOS 26.1. Release Date Given that Apple has yet to seed an iOS 26.1 Release Candidate, which is typically the final beta version, the...
iOS 26

6 New Things Your iPhone Can Do in iOS 26.1

Wednesday October 29, 2025 4:22 am PDT by
Apple is about to drop iOS 26.1, the first major point release since iOS 26 was rolled out in September, and there are at least six notable changes and improvements to look forward to. We've rounded them up below. Apple has already provided developers and public beta testers with the release candidate version of iOS 26.1, which means Apple will likely roll out the update to all compatible...
maxresdefault

Apple TV 4K Could Still Launch Before 2025 Ends: All the Rumored Features

Monday October 27, 2025 4:51 pm PDT by
Apple is designing an updated version of the Apple TV 4K, and rumors suggest that it could come out sometime in the next couple of months. We're not expecting a major overhaul with design changes, but even a simple chip upgrade will bring major improvements to Apple's set-top box. Subscribe to the MacRumors YouTube channel for more videos. We've rounded up all the latest Apple TV rumors. ...
iOS 26

Apple Seeds iOS 26.1, iPadOS 26.1, and macOS Tahoe 26.1 Release Candidates

Tuesday October 28, 2025 1:07 pm PDT by
Apple today provided developers and public beta testers with the release candidate versions of upcoming iOS 26.1, iPadOS 26.1, macOS Tahoe 26.1, tvOS 26.1, watchOS 26.1, and visionOS 26.1 updates for testing purposes. The RCs betas come a week after Apple released the fourth betas. The new betas can be downloaded from the Settings app on a compatible device by going to General > Software...
M6 MacBook Pro Feature 1

M6 MacBook Pro: Release Date, Pricing, and What to Expect

Monday October 27, 2025 9:15 am PDT by
Apple this month refreshed the 14-inch MacBook Pro base model with its new M5 chip, and higher-end 14-inch and 16-inch MacBook Pro models with M5 Pro and M5 Max chips are expected to follow in early 2026. However, these machines will represent the final update to the current design, with Apple reportedly developing a completely new version of the MacBook Pro packed with next-generation hardware...
iPhone 17 Pro Cosmic Orange

8 Reasons to Wait for Next Year's iPhone 18 Pro

Thursday October 30, 2025 4:42 am PDT by
Apple's iPhone development roadmap runs several years into the future and the company is continually working with suppliers on several successive iPhone models at the same time, which is why we often get rumored features months ahead of launch. The iPhone 18 series is no different, and we already have a good idea of what to expect for the iPhone 18 Pro and iPhone 18 Pro Max. One thing worth...
macos tahoe

Here Are Apple's Release Notes for macOS Tahoe 26.1

Tuesday October 28, 2025 1:21 pm PDT by
Apple today provided developers and public beta testers with the release candidate version of macOS Tahoe 26.1, which means the update will likely see a public launch next week. The release candidate includes notes on what's in the update, so we have a full picture of the new features that Apple has included. macOS Tahoe 26.1 adds AutoMix support over AirPlay, improved FaceTime audio...
ipad mini 7 feature blue

OLED iPad Mini: Release Date, Pricing, and What to Expect

Wednesday October 29, 2025 7:13 am PDT by
Rumors are stoking excitement for the next-generation iPad mini that Apple is reportedly close to launching. So what should we expect from the successor to the iPad mini 7 that Apple released over a year ago? Read on to find out. Processor and Performance Apple is working on a next-generation version of the iPad mini (codename J510/J511) that features the A19 Pro chip, according to...
iPhone Car Key Kia

Another Vehicle Brand Gaining iPhone Car Keys Support

Tuesday October 28, 2025 5:27 am PDT by
Apple is preparing to bring support for its digital car key feature to Jetour vehicles, according to evidence uncovered on Apple's backend by MacRumors contributor Aaron Perris. Introduced in 2022, Car Keys allows an iPhone or Apple Watch to unlock a vehicle through the Wallet app. A digital version of a car key is stored in Wallet, and unlocking can be done by holding an Apple Watch or...

Top Rated Comments

pgiguere1 Avatar
173 months ago
They still did it with the nano:

Score: 30 Votes (Like | Disagree)
FSMBP Avatar
173 months ago
I love stories like this (along with the other prototype leaks/stories). It gives such great insight into Apple & how they operate/think.
Score: 20 Votes (Like | Disagree)
chainprayer Avatar
173 months ago
Avoiding antenna issues? Dodged a bullet on that one!
Score: 14 Votes (Like | Disagree)
twietee Avatar
173 months ago
Glad they thought twice about printing "MENU" on the home button.

The first one looks pretty slick imho, reminds me on a cooler Vertu version. I'd buy that.
Score: 14 Votes (Like | Disagree)
Jynto Avatar
173 months ago
They still did it with the nano:

Image (http://www.wikinoticia.com/images2//alt1040.com/files/2011/09/ipod_nano_curved_cover_glass1.jpg)

That wasn't a touchscreen though.
Score: 10 Votes (Like | Disagree)
jasonxneo Avatar
173 months ago
It was rejected cause it looked ugly hahahaha!! :D
Score: 10 Votes (Like | Disagree)