iPhone Air and Apple Watch parts are made from 3D printed titanium
Some of the Apple Watch models, including the Apple Watch Ultra 3 and Apple Watch Series 11, released in September 2025, feature titanium cases. The titanium cases are actually made using a 3D printer, and Apple has provided details about the manufacturing process.
3D-printed Apple Watch titanium case paints a picture of the future - Apple (UK)
The Apple Watch's titanium case is made from 60-micrometer-thick layers of '100 percent recycled, aerospace-grade titanium powder.' The titanium is in the form of a powder with a diameter of 50 micrometers, and the oxygen content is finely tuned to reduce titanium's explosive properties when exposed to heat.
Each 3D printer is equipped with six lasers, and all six lasers are operated simultaneously to produce a large number of cases. 3D printers are often used for the production of prototypes, but Apple's major feature is that it is also using 3D printers to manufacture the final product.
Once the case is formed, the powder removal process begins.
The powder removal process is divided into 'rough powder removal' and 'precise powder removal,' and an ultrasonic sieve is used in the precision process.
Once the powder has been removed, coolant is sprayed onto the cases to cool them down while thin wire is used to separate the cases.
Quality inspection is then carried out using an automated optical inspection system.
Once the parts pass quality inspection, they undergo final machining. Using a 3D printer allows for texture printing, which is not possible with conventional casting processes, and is helping to improve the waterproofing process for the antenna housing. Furthermore, compared to conventional methods, the amount of material required is halved, saving more than 400 tons of titanium raw material in 2025 alone.
3D printing of titanium is used not only for the Apple Watch case, but also for the USB port on the iPhone Air, which Apple claims is both thin and durable.
The iPhone Air and Apple Watch Ultra 3 are also available on Amazon.co.jp. At the time of writing, the 256GB iPhone Air is available for 159,799 yen (tax included). The 49mm black titanium case and black ocean band Apple Watch Ultra 3 is also available for 127,178 yen (tax included).
Amazon.co.jp: Apple iPhone Air 256GB (SIM-Free): The thinnest iPhone ever, featuring a 6.5-inch display with ProMotion up to 120Hz, a powerful A19 Pro chip, a center-frame front camera, and all-day battery life; Cloud White: Electronics & Cameras
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in Hardware, Smartphone, Posted by log1o_hf