In a new press release, Apple goes in-depth on how it has leveraged 3D printing in the manufacturing process of this year’s Apple Watch Series 11 and Apple Watch Ultra 3.
For the first time, both models are made with 100 percent recycled aerospace-grade titanium powder, something Apple says was “not previously considered possible at scale.”
The manufacturing breakthrough has led to significant improvements in the environmental impact of Apple Watch production.
Using 3D printing to make Apple Watch
Apple explains that it had to strike a balance between perfecting the use of 3D printing while retaining the durability and design elegance of the Apple Watch:
This year, all Apple Watch Ultra 3 and titanium Apple Watch Series 11 cases are 3D-printed with 100 percent recycled aerospace-grade titanium powder, an achievement not previously considered possible at scale. Every team at Apple rallied behind a shared ambition. The polished mirror finish on Series 11 had to be pristine. Ultra 3 had to maintain its durability and lightweight form to meet the demands of everyday adventurers. They both also had to be better for the planet without compromising performance, and use the same or better-quality materials.
The press release continues:
Using the additive process of 3D printing, layer after layer gets printed until an object is as close to the final shape needed as possible. Historically, machining forged parts is subtractive, requiring large portions of material to be shaved off. This shift enables Ultra 3 and titanium cases of Series 11 to use just half the raw material compared to their previous generations.
Apple says that this innovative process has led to raw titanium savings of more than 400 metric tons in 2025. Apple Watch Series 11 and Apple Watch Ultra 3 use 50% less raw material than previous generations.
“A 50 percent drop is a massive achievement — you’re getting two watches out of the same amount of material used for one,” explains Sarah Chandler, Apple’s vice president of Environment and Supply Chain Innovation. “When you start mapping that back, the savings to the planet are tremendous.”
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