‘Imagine an automated torture chamber’: I visited Samsung's South Korea factory to see how its Galaxy foldables are tested — and these robots don't miss a beat

Imagine an automated torture chamber where one calamity after another is inflicted upon you. Worse yet, it’s all robots doing the pushing, pulling, pressing, switching, and lighting. A robot even delivers you to this house of horrors.

Of course, you’re a Samsung Galaxy phone, and you were actually built to take this kind of punishment, or at least expected to survive it. Housed in a basketball court-sized room, this is one of Samsung’s endlessly running test suites for its growing line of Samsung Galaxy S series and Galaxy Z folding phones.

A few weeks ago, Samsung flew me out to South Korea to visit its Gumi factory where, among other things, they build and stress test their newest phones, including the Galaxy Z Fold 8, Galaxy Z Fold 8 Ultra, and Galaxy Z 8 Flip, all of which were introduced this week at Samsung Galaxy Unpacked in the UK.

As a lab engineer guided us through the space, a robot waited impatiently behind him while trying to deliver more phones to its Guantanamo of tech indignities. The engineer seemed unconcerned as the robot edged closer to us, but it always remained a safe distance away, finally delivering a phone to the first chamber when we’d cleared a path.

Of course, before Samsung checks the viability of these handsets, it builds them.

Make 'em and (try to) break 'em

When I visited the factory — one of nine dotted around the globe and where millions of units are assembled — for the first time a few years ago, I noticed a mix of robots (not humanoid, just automated platforms and a wide variety of robot arms) and humans. This time, however, there were just a handful of humans, who were often checking the robots’ work for imperfections.

As we walked the pristine aisles while wearing thin, blue protective covers on our shoes, I caught the eye of one factory worker and gave her a thumbs up. To my surprise, she smiled and nodded back at me before quickly returning to product inspections.

Across a series of metal and plexiglass boxes, I saw all manner of robots and mobile device manufacturing activity. There was never a pause or moment of indecision. In one enclosure, I watched as camera boards were robotically placed in a Galaxy Z Fold 8 Ultra board and then expertly screwed into place.

Virtually every robot in every enclosure has a specific job, like the one that does nothing but remove thin-blue packing material from a phone circuit board. Its tiny fingers delicately grab a pair of thin blue tabs and strip away the filament. We found ourselves cheering on the little bot.

In another spot, a colleague noticed that a copper line wasn’t properly affixed to a phone’s main circuit board. I could see it bouncing freely and wondered if the error would be caught or end up in someone’s wonky Galaxy device. I needn’t have worried. Samsung’s automated systems are fully capable of both the build and error-catching. As we watched, the offending board shifted off course and was held at bay while other properly built boards moved along.

I saw many different enclosures with so many automated manufacturing capabilities that it was mind-boggling.

Box 'em up but test them first

In another space, I saw sensors identifying phone IMEI numbers, while another robot printed out corresponding labels, and then a third affixed them to boxes that matched the packages to each phone.

Most of the robots I saw were small, but at the end of the line was an almost car-sized palletizer that takes the 10-per-box cardboard crates and stacks them on a pallet, placing the boxes first around the perimeter and then filling in the middle. The motorcycle-sized arm was remarkably fast and accurate.

Some of the phones never make it to the pallet. Instead, a select few are destined for a special test room where a large horseshoe of enclosures determines if the models in the current batch are fit for purpose.

There are two types of test systems in Gumi: the boxes that run the same test over and over again in a single device, and the U-shaped automated test bay where one phone is run in serial through the entire array of tests. These tests will often replicate what is done repeatedly in other enclosures.

The number of test systems and kinds of tests Samsung runs on its products is impressively comprehensive, though some of the boxes look downright bizarre.

Weird tests, reliable products

Folding and unfolding the devices thousands of times is to be expected, as is pressure testing, but I also saw extreme heat and cold tests. There were also enclosures that do nothing but check AI vision systems, millimeter wave, waterproofing, and a facial recognition chamber with life-like mannequin heads that I can still see when I close my eyes.

There’s even a room where partners like Google can remotely access and run tests on Samsung phones.

More astonishing is that this is a living, ever-changing facility. Just imagine what happens every time, like now, Samsung unveils new phones and watches; they must retool. Walking the floor, I noticed how the brand-new Galaxy Z Fold 8 was already undergoing rigorous tests. The lab engineer told us, “For every new form factor, we develop new technology for it,” and they develop new automation to test it.

Look, I’m not saying other companies don’t put their mobile hardware through similar wringers, but I’m not sure any other tech giant has been so transparent about their process. It’s wild, bracing, and I must admit, gives me more than a bit of confidence about each new Galaxy device Samsung delivers.

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