Apple has introduced 3D-printed titanium in several of its devices, showcasing a step-by-step process and the benefits of this technology. The titanium cases for the Apple Watch Ultra 3, the high-end Apple Watch Series 11, and the USB-C port on the iPhone Air are all crafted using 100% recycled aerospace-grade titanium powder. This additive manufacturing process builds objects layer by layer, minimizing waste compared to traditional forging methods.
The company claims that 3D printing allows the new Apple Watch models to use only half the raw material of their predecessors, potentially saving over 400 metric tons of titanium this year. This aligns with Apple’s goal of achieving carbon neutrality by 2030. The Vice President of Environment and Supply Chain Innovation noted that this 50% reduction in material usage is a significant achievement.
Beyond environmental advantages, 3D printing enhances the waterproofing of cellular Apple Watch models by improving the bond between the metal case and the plastic strip for antenna signals. The iPhone Air’s 3D-printed USB-C port is touted to be thinner, stronger, and uses 33% less material than conventionally forged counterparts.
The process for creating these titanium cases involves atomizing raw titanium into powder, using lasers to build the cases layer by layer, removing excess powder, and conducting a final quality check.
