Apple explored whether 3D printing could shift from prototyping to producing millions of high-precision titanium enclosures using recycled material. This effort led to the 3D-printed titanium cases used in Apple Watch Ultra 3, Apple Watch Series 11, and the titanium USB-C port on the new iPhone Air. The process uses 100 percent recycled aerospace-grade titanium powder and reduces raw material use by around half compared to previous generations, saving more than 400 metric tons of titanium in 2025.
Teams across product design, manufacturing, and environmental engineering refined the approach through continuous prototyping, alloy tuning, and process optimisation. Six-laser printers build each case in over 900 layers, followed by detailed depowdering, singulation, and optical inspection. The precision of the additive process enabled improvements such as enhanced bonding for cellular antenna components and greater design flexibility.
Apple views this shift as part of its broader Apple 2030 plan to reach carbon neutrality across its operations, supply chain, and product use.
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