How Apple creates new titanium components using 3D printing Apfelpatient

Apple is increasingly relying on 3D printing, demonstrating how modern manufacturing saves resources, improves product quality, and paves the way for greater sustainability. The current use of 3D-printed titanium in the Apple Watch Ultra 3, the Apple Watch Series 11, and the iPhone Air shows how far this technology has already come in everyday life.

The use of 100 percent recycled, aerospace-grade titanium powder plays a central role at Apple. Through additive manufacturing from metal powder, only the material that is actually needed is produced. This process differs significantly from traditional forging methods, where large quantities of raw material are lost through milling and machining. This is precisely where the advantage for Apple becomes apparent, both technically and ecologically.

How Apple uses 3D printing for titanium

In 3D printing, a component is built layer by layer from powdered titanium. The laser builds the shape so precisely that it closely resembles the final geometry. This not only reduces waste but also the amount of titanium that Apple needs to purchase and process.

According to Apple, this process for the Apple Watch Ultra 3 and the titanium models of the Apple Watch Series 11 requires only half the amount of raw material compared to the previous generation. This translates to an estimated saving of more than 400 tons of raw titanium this year. This move brings Apple closer to its goal of achieving carbon neutrality across the entire company by 2030.

Sarah Chandler, Apple's Vice President of Environment and Supply Chain Innovation, describes the 50 percent savings as significant. The amount of titanium previously used for a single watch now makes two.

Improvements through 3D printing in Apple Watch models

The technology offers more than just environmental benefits. The cellular models of the Apple Watch benefit from a better connection between the metal casing and the thin plastic strip for the antenna. The more precise manufacturing process also improves water resistance, as the interfaces are cleaner and more stable.

Why the iPhone Air benefits from 3D printing

The iPhone Air also uses 3D-printed titanium. Its USB-C port is made entirely of recycled titanium powder and offers three clear advantages compared to conventionally manufactured ports: it's thinner, stronger, and requires 33 percent less material. This saves resources and simultaneously improves the component's robustness.

The manufacturing process at a glance

Apple describes the entire process transparently. First, titanium is ground into a fine powder. Then, a machine builds the components layer by layer using lasers. Once the shape is complete, excess powder is removed. Apple then separates the individual casings and subjects them to a final quality inspection. Only then do they proceed to the next stage of production and are later integrated into the devices.

How Apple combines technology and the environment

The use of 3D-printed titanium demonstrates how Apple is modernizing manufacturing processes and using materials more efficiently. The combination of recycled raw material, precise laser manufacturing, and clear environmental goals simultaneously improves stability, water resistance, and resource conservation. This development shows how Apple is blending technological innovation and sustainability, setting standards for future product generations. (Image: Apple)