In a new press release, Apple details how it leveraged 3D printing in the manufacturing process for 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, which Apple says was “previously thought impossible to use at scale.”
Manufacturing breakthroughs have significantly improved the environmental impact of Apple Watch manufacturing.
Making an Apple Watch using 3D printing
Apple explains that they needed to strike a balance between perfecting the use of 3D printing while maintaining the durability and elegance of the Apple Watch’s design.
This year, all Apple Watch Ultra 3 and titanium Apple Watch Series 11 cases are 3D printed using 100% recycled aerospace-grade titanium powder. This is an accomplishment previously thought impossible at scale. All teams at Apple are united by a common ambition. The Series 11’s polished mirror finish had to be clean. The Ultra 3 needed to maintain a durable and lightweight profile to meet the demands of everyday adventurers. Both also had to be better for the planet without compromising performance, and they had to use materials of the same or better quality.
The press release continues:
Using the additive process of 3D printing, we print layer after layer until the object is as close to the desired final shape as possible. Historically, machining forged parts has been subtractive, requiring large portions of material to be removed. This change means that the Series 11 Ultra 3 and Titanium cases use only half the raw materials compared to the previous generation.
Apple says this innovative process will save more than 400 tons of titanium raw materials by 2025. Apple Watch Series 11 and Apple Watch Ultra 3 use 50% less raw materials than the previous generation.
“A 50% reduction is a huge accomplishment; you get two watches out of the same amount of material that goes into one watch,” explains Sarah Chandler, Apple’s vice president of environmental and supply chain innovation. “If you start mapping that backwards, there will be huge savings for the planet.”
Apple emphasizes that all of this is being done towards its Apple 2030 goal of becoming carbon neutral across its footprint by the end of the decade. “Already, all the electricity used to manufacture Apple Watch comes from renewable energy sources like wind and solar,” Apple says.
3D printing also enabled important upgrades to Apple Watch Series 11 and Apple Watch Ultra 3. This is an improved waterproofing of the antenna housing for cellular models.
Beyond the Apple Watch, Apple’s 3D printing efforts have allowed it to create a USB-C port thin enough for the iPhone Air’s 5.6mm chassis.
This design flexibility unlocked another advantage over the Apple Watch. That’s the USB-C port on the new iPhone Air. By using the same recycled titanium powder to create an all-new port with a 3D-printed titanium casing, Apple was able to achieve an incredibly thin and durable design.
The full press release can be viewed on Apple’s website. This is an interesting look at all the manufacturing technology behind the Apple Watch Series 11 and Apple Watch Ultra 3, and the benefits they offer as a result.
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