New Delhi: Apple has recently taken a significant step in its manufacturing strategy by adopting fully 3D-printed titanium cases for the Apple Watch Ultra 3 and Apple Watch Series 11. The company has also stated that this move supports its long-term environmental roadmap and reduces the amount of raw material needed for production. Both the latest models now rely on 100% recycled aerospace-grade titanium powder for their external shells, which will mark a complete shift from the earlier forging methods. Apple has replaced the earlier practice of shaping cases from the large titanium blocks with an additive production method.
The latest process builds each watch case layer by layer, and every unit goes through more than 900 printed layers before entering the finishing stage. According to the company, this approach cuts the raw titanium use by nearly half when compared to its previous techniques. Apple engineers explain that the transition follows several years of internal testing. They have evaluated allowed mixes, powder behaviour, oxygen balance and print speeds before arriving at the design that could run reliably. The printers use six lasers that operate without pause, which creates structures that need only cleaning, trimming and inspection before the final assembly.
Apple has estimated that the latest method will save more than 400 metric tons of raw titanium in 2025. The titanium used in the production appears in powder form at a thickness of 50 microns. Laser fuses the material with precise control, which Apple stated keeps the required durability for daily wear. The shift is part of the company’s plan to reach carbon neutrality across its business and supply chain by 2030. Furthermore, the company adds that the latest printing method gives engineers the freedom to design internal features that forging could not accommodate. Apple has also shared that the same recycled titanium powder is now used in the USB-C port design of the latest iPhone Air. This suggests that Apple may adopt 3D-printed titanium parts in future releases.
