Originally published at: https://tidbits.com/2025/11/21/inside-apples-3d‑printed-titanium-apple-watch-cases/
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.
Modern-day manufacturing is impressive enough in its own right, but Apple’s move to 3D printing Apple Watch cases at scale marks a significant milestone. Because 3D printing is an additive process that uses only the material in the final part, unlike subtractive machining of forged parts that results in significant waste, Apple says it uses 50% less raw material than in previous generations and expects to save over 400 metric tons of titanium in 2025. Over 20 hours, six lasers fuse more than 900 layers of recycled titanium powder to create a single Apple Watch case. Read the article for more over-the-top details and example videos.