Inside OpenAI and Jony Ive’s Secretive AI Device Project: What We Know So Far
OpenAI and Jony Ive’s io are developing a new AI hardware device, exploring various formats beyond wearables. The product is expected to launch in over a year.

OpenAI and Jony Ive’s io: Inside the Development of a New AI Hardware Device
Recent legal filings from OpenAI and Jony Ive’s io reveal fresh insights into their collaboration to build a mass-market AI hardware device. These documents surfaced amid a trademark dispute with iyO, a Google-backed startup focusing on custom-molded earpieces that connect to other devices.
OpenAI recently removed promotional materials related to its $6.5 billion acquisition of io to comply with a court order tied to the lawsuit. The company denies allegations of trademark infringement made by iyO.
Research and Development Focus
According to filings, OpenAI executives and former Apple leaders at io have spent the past year researching in-ear hardware devices. On June 12, their lawyers disclosed that the companies purchased over 30 headphone sets to analyze current market offerings. They have also met with iyO’s leadership, demonstrating their own in-ear technology during these discussions.
Despite this focus, OpenAI’s first hardware product with io might not be headphones at all. Tang Tan, io’s co-founder and chief hardware officer, stated in a court declaration that the prototype mentioned by OpenAI CEO Sam Altman “is not an in-ear device, nor a wearable device.” The design remains unfinished and the product is expected to be at least a year away from launch.
What Could the First Device Be?
The exact form factor for the first OpenAI/io device remains unclear. In io’s launch video, Altman described the plan to build a “family” of AI devices with various functions. Ive expressed that the first prototype “completely captured” his imagination. Altman also told OpenAI employees that the device would be small enough to fit in a pocket or sit on a desk and would serve as a “third device” alongside smartphones and laptops.
In court, Altman emphasized that their goal is to create products that go beyond traditional interfaces. OpenAI’s filings mention exploring a variety of form factors, including desktop-based, mobile, wired, wireless, wearable, and portable devices.
Industry Context: AI-Enabled Devices
Smart glasses are currently a leading form factor in the AI device race, with companies like Meta and Google pushing for mass adoption. At the same time, AI-enabled headphones are gaining attention. Apple, for example, is reportedly developing AirPods equipped with cameras to enhance AI features by collecting environmental data.
Interactions with iyO and Product Insights
OpenAI’s VP of Product, Peter Welinder, and Tan met with iyO’s CEO, Jason Rugolo, in May to learn more about iyO’s custom-fit earpiece. This meeting took place at io’s San Francisco office. Despite testing the product, Welinder and Tan were disappointed by repeated failures during demonstrations.
Tan stated that he attended the meeting as a courtesy to his mentor, former Apple executive Steve Zadesky, who recommended the discussion. He also took steps to avoid accessing iyO’s intellectual property, including having lawyers review materials first.
iyO customizes its in-ear devices using detailed ear scans collected by a specialist from The Ear Project. Within the legal documents, Marwan Rammah, a former Apple engineer now at io, suggested purchasing a large database of 3D ear scans to aid ergonomic design, but it’s unclear if this deal proceeded.
Business Negotiations and Future Plans
Rugolo made several attempts to build a partnership or investment relationship with OpenAI and io, including offering to sell iyO for $200 million and proposing an early “developer kit” launch. These offers were declined, according to Tan’s declaration.
Evans Hankey, io’s co-founder and chief product officer, confirmed in court that io is not developing a custom-molded earpiece product. OpenAI and io appear to be at least a year away from selling their first hardware device, which may take a different form factor altogether.
Key Takeaways for Product Developers
- OpenAI and io are exploring various AI hardware formats beyond traditional wearables.
- Legal challenges can impact product announcements and marketing materials.
- Early-stage hardware development involves extensive market research and hands-on testing of existing products.
- Partnership discussions with competitors can be complex and require careful IP considerations.
- The timeline for bringing innovative AI devices to market can span multiple years.
For professionals interested in AI hardware development and product innovation, this case highlights the importance of thorough research, legal awareness, and strategic collaboration. To learn more about AI technologies and product development, check out Complete AI Training’s latest courses.