Apple Unveils New 3D-Printed Titanium Cases for Apple Watch Ultra 3 and Series 11

Apple is taking a major step forward in manufacturing and sustainability with the introduction of 3D-printed titanium cases for the new Apple Watch Ultra 3 and the titanium Apple Watch Series 11. The company has confirmed that this marks its first large-scale use of additive manufacturing, a milestone that aligns closely with its goal to become carbon neutral across its entire footprint by 2030. The shift to 3D printing also represents a significant leap in efficiency. The new process uses 100 percent recycled aerospace-grade titanium powder and already runs on 100 percent renewable electricity—including wind, solar, and hydropower sources. A More Efficient Way to Build Titanium Traditional titanium case production relies on forging, a subtractive process that begins with large blocks of metal and removes material until the final shape emerges. Apple’s new method flips that approach. By using additive 3D printing, each watch case is built layer by layer to near-final form, dramatically reducing waste. According to Apple, the change cuts the amount of raw titanium needed by more than half. The company estimates this transition alone will save over 400 metric tons of titanium in the first year. This improvement is a major contributor to Apple’s long-term environmental strategy. Sarah Chandler, Apple’s vice president of Environment and Supply Chain Innovation, highlights the shift as a “dramatic improvement in material efficiency,” emphasizing its importance to the Apple 2030 mission. A Decade in the Making Apple’s vice president of Product Design, Kate Bergeron, revealed that Apple has spent the last ten years perfecting this technology. It begins by converting raw titanium into a fine powder through a process called atomization. Managing oxygen levels during this step is critical—too much oxygen can weaken the final printed structure. Each case is then built using a bank of six precision lasers, printing layers that are just 60 microns thick. After printing, the cases undergo: Rough and fine depowdering Automated optical inspection Final machining and finishing The result is a highly durable titanium case with far less material waste. Design Benefits Beyond Sustainability The move to 3D printing isn’t just about efficiency. It has also enabled new design possibilities that weren’t achievable with forging. For example, on cellular Apple Watch models, Apple has 3D-printed a specialized inner texture that improves bonding between the titanium shell and the plastic antenna housing. This enhancement strengthens waterproofing and boosts overall structural integrity. Expanding 3D Printing Across Apple’s Lineup This advanced manufacturing technique isn’t limited to the Apple Watch. Apple has also used it to create the titanium USB-C port in the new ultra-thin iPhone Air. Bergeron says the breakthrough at scale gives Apple “even more design flexibility than what we had before,” hinting that additional products may adopt similar construction in the future. A Major Step Toward the Future of Apple Hardware Apple’s move to additive manufacturing represents a meaningful evolution in how the company builds its most durable devices. By combining sustainability, long-term design investment, and advanced material engineering, Apple is reshaping the future of hardware production. As Apple continues to refine the process, it wouldn’t be surprising to see more 3D-printed components across the product lineup in the years ahead.