Hello everyone,
Problem SORTED!!! It's a design flaw with the new MacBook Pro. Also, the thermal aspect of the machine contributes towards the problem.
More info: - I bought 2016 MacBook Pro 15" model in Feb, and the problem started 2 months later, I got in touch with the support online and booked in for the check up. The guys from Genius Bar looked at it for a day and refused to do anything as Engineers from Apple have deemed this problem as "Cosmetic Issue". So, I couldn't argue much. The problem continued, and the laptop started making noise while the opening of the display panel and when display panel was touched or moved. The sound was getting louder day by day. So I booked in another check up and had to fight with guys from Genius Bar and kept telling him its a design flaw and problem is with the display. I was able to produce the noise at the store. After lengthy discussion and argument, they agreed to replace the display, and they told me, if the problem persists, they won't be able to do anything about it anymore. I had no other option other than accepting the terms, which was demeaning as a customer.
So, they took a week to get the display replaced and didn't had any courtesy to contact me for updates, instead, I had to call them to check the status of the repair.
They have replaced display and I noticed some damages to the display wire connector ribbons, from underneath the hinge. I was a bit suspicious about the workmanship since the laptop didn't make any popping noise, I didn't raise the issue.
The laptop was working fine for a week and heard few very quite popping sounds. After a week, I realised there was another problem with the laptop's display. I knew where it was coming from. It was actually from the damaged connect ribbons to display, caused during the repair by technicians from Apple store. I heard abrasive noise from the body, close to the "Macbook Pro" label on the display, every time I opened the display to max viewing angle. I could feel the vibration due to the abrasion. It felt as if the top body panel was lifted. I contacted Apple support immediately and booked int another check up session to the same store.
I went to the store and explained them the situation. I was able to reproduce the sound and showed how body vibrated during the opening and closing. They got back to me saying,
"
We understand your problem and can't do much about it.. blah blah blah.....
"
at the end they said
"
It's a problem with the Macbook Pro and you to leave with it forever!
"
I was furious with the customer service and incapability to accept the problem and to deal with it.
I am a mechanical and thermal engineer by profession and understand system quite well. I did this before going to Apple for the first time but didn't get around the problem and I thought there was a problem with the torsional spring in the hinges, which are hidden behind the display and I can't take them without splitting the display apart.
So, this time I started playing with the laptop and was trying to simulate the behaviour. After looking at the machine for hours, I confirmed it is a design flaw.
You can see the cables and antenna if you turn the laptop upside down and look around the hinge area. Antenna body has a gap through which the whole cable assembly passes by. The flat/horizontal section in this region has sharp edges on both sides, through which the display cable pass over. The display wire connector is pushed against the sharp end of the Antenna body, by the flat ribbon. The popping noise is a combination of how this whole assembly works together. Once the laptop has used for months, by which I mean, the display is opened and closed, regularly. The flat wire kinds of bends over the sharp edges and starts to leave some mark and forms some dents on the flat wire caused as the flat ribbon pushing the wire against the edge. I have noticed this in my display wire. Part of was which damaged during the repair, which was causing this abrasive sound and which made me look into the problem.
The noise during the opening of the laptop is due to the sudden release of the stuck cable onto the sharp edges and spring hitting the body, which is attached to the ribbon for retraction and screwed it onto the body.
The heat released by the machine also helps to deform the structural integrity of the plastics around the wire.
I hope Apple soon be able to correct this design flaw!
All the best guys!
<Edited by Host>