User replaceable doesn't need to mean tool-free removal.
You can use tiny phillips/hex/torx screws instead of glue to hold the back in place.
You can use thin rubber gaskets and silicone grease to seal the case instead of a custom punched adhesive sheet that is nearly impossible to replace without destroying the device or compromising future water resistance. Literally every water resistant wristwatch made before Apple entered the market used to work this way. They're designed to have batteries replaced or mechanical bits serviced every few years and are expected to continue to be water resistant, and many of them are extremely thin. I'm surprised that no phones do this, as it seems like it could be marketed as a super premium build-quality feature ("built like a dive watch").
The batteries are already connectorized instead of soldered. You can use replaceable pull-tab-removable adhesive strips to hold the battery in place if needed, instead of glue that exceeds the yield strength of the material it's attached to.
Some of these things might cost a few cents more, but none of them should materially affect thinness, rigidity, water resistance, etc.
Gluing everything together will absolutely affect your drop tests, and your conversations with ID, and your conversations with manufacturing who don’t want to have 18 screws in the assembly. There are many more stakeholders other than consumers and evil bean counters who don’t want you buy a third party battery. I’ve seen drop tests alone dictate the use of adehesives.
You can use tiny phillips/hex/torx screws instead of glue to hold the back in place.
You can use thin rubber gaskets and silicone grease to seal the case instead of a custom punched adhesive sheet that is nearly impossible to replace without destroying the device or compromising future water resistance. Literally every water resistant wristwatch made before Apple entered the market used to work this way. They're designed to have batteries replaced or mechanical bits serviced every few years and are expected to continue to be water resistant, and many of them are extremely thin. I'm surprised that no phones do this, as it seems like it could be marketed as a super premium build-quality feature ("built like a dive watch").
The batteries are already connectorized instead of soldered. You can use replaceable pull-tab-removable adhesive strips to hold the battery in place if needed, instead of glue that exceeds the yield strength of the material it's attached to.
Some of these things might cost a few cents more, but none of them should materially affect thinness, rigidity, water resistance, etc.
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