Overview
- Apple says every Apple Watch Ultra 3 and titanium Apple Watch Series 11 case is now 3D-printed using 100% recycled aerospace-grade titanium powder, with the process scaled to full production.
- The additive approach cuts raw titanium per case by about 50%, with Apple estimating more than 400 metric tons saved in 2025.
- Apple’s workflow atomizes low-oxygen titanium powder and uses six-laser printers to build roughly 900 layers at about 60 microns, followed by depowdering that recycles unused material and automated optical inspection.
- Engineers 3D-printed interior textures that improve bonding for the cellular antenna housing, which Apple says enhances waterproofing without changing exterior design.
- The same recycled titanium printing method is used for the iPhone Air’s USB‑C port, and Apple notes Apple Watch manufacturing runs on renewable electricity.