Editor
Jodee Tan chevron_right
Apple has proudly shared a new tech feat for its Apple Watch lineup that was originally thought of to be difficult in going full scale with—fully 3D-printed cases made from 100 percent recycled aerospace-grade titanium powder.
This means shoppers buying the Apple Watch Ultra 3 and the titanium variants of the Series 11 will enjoy them with just-as-durable sporting cases that redefine what sustainable manufacturing can look like in consumer tech.
From Waste to Wrist
Behind traditional watchmaking are practises that often end up a wasteful act. Historically, manufacturers would start with large chunks of titanium and machine away huge portions of material just to achieve the shape needed. This becomes a subtractive process that leave mountains of high-grade metal on the cutting room floor.
Apple has decided to flip the script entirely. Using 3D printing's additive approach, the company built its Watch cases layer by layer, printing just what's needed until the case is as close to its final form as possible. The result? Apple's Watch Ultra 3 and titanium Series 11 cases now use just half the raw material compared to their previous generations.
This may seem like a small improvement, but it's a massive shift in how the industry can utilise on reforging used metal for repurpose. Apple estimates more than 400 metric tons of raw titanium will be saved this year alone thanks to this new manufacturing process. That's about the weight of 50 fully-loaded semi-trucks' worth of premium metal that won't end up as scrap.
No Compromises on Design or Durability
Not giving into the industrial demands of producing in volume, Apple managed to pull this off while maintaining the design integrity and exceptional durability standards the brand is known for. These aren't prototype-grade products or limited editions with asterisks attached. These are full-production Apple Watches that meet the company's exacting standards, right down to the last detail.
This wasn't an overnight achievement either. The journey to production-scale 3D-printed titanium cases was a multiyear endeavour that started with demos and proofs of concept. Apple's engineering team had to fine-tune everything from the specific alloy composition to the printing process itself. After testing on a much smaller scale, they gained confidence in their ability to tackle the unique challenges that come with working with titanium—a notoriously difficult material to manipulate.
Beyond the Watch: A Glimpse of What's Next
The benefits of mastering 3D-printed titanium extend beyond Apple Watch. Take the new iPhone Air, for example. The device features a USB-C port with a titanium enclosure that's 3D-printed using the same recycled titanium powder. This breakthrough enabled Apple to create an incredibly thin yet durable design that simply wouldn't have been possible with traditional manufacturing methods.
Watch our video below for a clearer picture:
View this post on Instagram
Charging Towards Carbon Neutrality
These accomplishments further contribute to Apple's relentless pursuit of its 2030 goal: to be carbon neutral across the company's entire footprint by the end of this decade. Already, all of the electricity used to manufacture Apple Watch comes from renewable energy sources like wind and solar.
As consumers become increasingly conscious of the environmental impact of their tech purchases, innovations like these show that premium products and planet-friendly practices don't have to be mutually exclusive.
Want to learn more about Apple's environmental initiatives? Check out Apple's 2030 carbon neutrality roadmap to see how the company plans to achieve its ambitious climate goals.
Stay updated with ProductNation on here, Instagram & TikTok as well.
Read more news on ProductNation: