Apple brings 3D-printed titanium cases to Apple Watch Ultra 3 and Series 11

Watch Ultra 2

Apple has introduced a new manufacturing shift for Apple Watch Ultra 3 and Apple Watch Series 11 by moving entirely to 3D-printed titanium cases. The company says the transition enables better material efficiency while supporting its Apple 2030 environmental targets. Both models now use 100 percent recycled aerospace-grade titanium powder for their external enclosures.

How the new 3D-printing process works
Instead of machining large blocks of titanium, Apple is using an additive printing process that builds each case layer by layer. Each case requires more than 900 printed layers before it moves into finishing. Apple says the approach lets it use nearly half the raw titanium previously required for its forged designs.
Engineers say the shift was made possible after years of testing alloy compositions, powder properties, oxygen levels and laser-based printing speeds. Apple uses six-laser printers that run continuously, creating near-final case structures that require only cleaning, cutting and inspection before assembly.

Material savings and environmental impact
Apple says the new production method will save more than 400 metric tons of raw titanium in 2025. The material is printed in 50-micron powder form and then fused using precise laser control to maintain structural durability. According to Apple, the switch is part of its broader plan to reach carbon neutrality across its operations and supply chain by the end of the decade.

Additional design benefits
The company says 3D-printing has enabled internal design changes not possible with traditional forging. One example is new internal textures inside cellular models, which support better bonding between titanium and plastic components used for antenna performance.
Apple also confirmed that the same recycled titanium powder is used in the new USB-C port design on the iPhone Air, suggesting that the process may extend to more Apple hardware in the future.