You just tap Buy Suica and insert two 1000 yen bills. The system keeps 500 yen as a deposit, which is refunded when you return the card, but it's also $3.50 for a little memorabilia.
If you absolutely don't want the keepsake, you can create a virtual card from Wallet on iPhone(7 or later). I believe an app is not needed through that path. Those can be loaded from your credit card, or at pink ticket vendors with the cavity for devices(IIRC the latter didn't work initially).
I believe you can't get a physical one from the ticket machines anymore unless you are getting a commuter pass, but I might be wrong.
Took me roughly a minute to create one within Apple Wallet ahead of my trip, and that was it. Didn't need to install any apps or register on any websites, because creating a Suica card is natively supported in the wallet app.
Idk how the situation is like with Suica card on Android though, outside of the fact that unless the phone was purchased in Japan, it will typically lack the necessary hardware for it (which isn't a concern with iPhones, because all regional versions include it).
The digital version only works on iPhones, since Android phones sold outside Japan doesn't have the Felica chip, or if they have it (e.g. Google Pixel) is disabled in EU/US firmware because the manufacturer doesn't want to pay a fee for every phone to Sony for something 99.999% of people that will never travel to Japan would use.
Totally forgot about that aspect, you are 100% correct.
I remember traveling with my friend who had a physical card, and more than once we had to reroute to a nearby kiosk and wait in line, so he could recharge the balance on the card. Apple Wallet felt more convenient, because recharging it was as simple as picking the amount to recharge and hitting "submit."
Your explanation makes more sense, because it is definitely cheaper/easier to just disable (but include) that hardware to avoid licensing fees (as opposed to having an additional factory manufacturing line just to produce the SKUs that physically exclude that hardware).
It used to be easy to get one from a 7-11, then it was hard for a bit, then it was easy again with digital wallets.
Anyway, that problem is long gone.
Maybe you can refill it with cash? Or did I have to buy it with cash? and when you leave everything expires.
I had to get 4 as I was traveling with kids who don't own phones and could get cheaper rates, took a few minutes, you waste a few yen but get to keep the souvenir.