The original Galaxy Fold weighed a hefty 276g, and the Z Fold2 was even heavier at 282g. Yet Samsung’s latest book-style foldable is only 201g. This progress stems from a relentless focus on reducing weight and thickness.

The Galaxy Z Fold7 achieved a major goal by weighing 215g—3g less than the Galaxy S25 Ultra. The new Z Fold8 Ultra matches that weight, but it hides significant engineering work. The battery grew from 4,400mAh to 5,000mAh, adding 6g, so Samsung had to compensate elsewhere.

To offset the heavier battery, engineers examined 270 components and 180 types of auxiliary parts. They removed 15 part types and slimmed others, saving fractions of a gram—some as small as 0.0001g. The new Ultra also added a larger graphite sheet for cooling and a 50MP ultra-wide camera, requiring further weight cuts.

The Folds have gotten significantly thinner since the original. Samsung reworked the internal structure and motherboard, and introduced the Flex Titanium design. This includes a titanium sheet only a few tens of micrometers thick—about one-third the width of a human hair—plus a 0.2mm titanium plate. Machining such thin materials risks bending, so Samsung rethought the entire process to ensure reliability.