Overview
- Apple confirms every Ultra 3 and titanium Series 11 case is produced with 3D printing using 100% recycled aerospace‑grade titanium powder.
- The additive process cuts raw titanium use by about 50%, with Apple estimating more than 400 metric tons saved in 2025.
- Engineers fine‑tuned powder oxygen levels and use six‑laser printers to build roughly 900 layers at about 60 microns per layer before automated inspection.
- Apple reports design gains including better bonding for cellular antenna housings that improves waterproofing while maintaining durability and finish.
- The same method prints the iPhone Air’s titanium USB‑C port enclosure, and Apple says all Apple Watch manufacturing runs on renewable electricity.