Editor’s Note
Apple’s shift to 3D-printed titanium cases for its latest watches marks a significant manufacturing evolution, aiming to reduce material waste and advance its sustainability targets.
Apple has introduced 100% 3D-printed titanium cases for its new Apple Watch Ultra 3 and Apple Watch Series 11. This means the outer parts of both watches are now made from recycled titanium powder. Apple states that this change saves material and will help the company achieve its 2030 environmental goals.
Previously, Apple used to cut cases from large titanium blocks. Now, the company employs layer-by-layer 3D printing. Over 900 layers are printed to create each case. This requires nearly 50% less titanium compared to the previous method.
According to Apple, this new method could save over 400 tons of titanium in 2025. The powder consists of very fine 50-micron particles, which are fused together by laser to create strength.
3D printing also allows Apple to create new designs. For example, some cases feature a special internal texture, which allows titanium and plastic parts to connect better and improves antenna performance.
Apple also revealed that this same recycled titanium powder is now being used in the new USB-C port of the iPhone Air. This indicates that this method could be used in more Apple products in the future.