For the very first time, the enclosures of both the Apple Watch Ultra 3 and the titanium Apple Watch Series 11 are being produced entirely through additive manufacturing using 100% recycled aerospace-grade titanium powder.
This is not a small experiment or a limited run. Apple’s design and engineering teams committed to scaling this process to mass production. To begin, they had to demonstrate through repeated prototyping and rigorous data collection that 3D printing could meet Apple’s exacting quality standards.
Sustainability was at the heart of the project. By shifting from traditional subtractive manufacturing, which discards large amounts of raw material, to an additive approach, Apple managed to cut the raw titanium used in each case by half when compared to prior generations. This dramatic reduction means that in 2025 alone Apple expects to save more than 400 metric tons of titanium.
Apple emphasized that the new process does not compromise performance or design. The Series 11 model had to retain its polished mirror finish while the Ultra 3 needed to remain rugged and lightweight to serve users who lead active, adventurous lives.
According to Sarah Chandler, Apple’s vice president of Environment and Supply Chain Innovation, 3D printing offered a powerful way to improve material efficiency and reduce waste. Apple already powers its manufacturing plants with renewable energy, and the adoption of additive manufacturing aligns closely with its broader climate-action goals.
From a technical standpoint, the production process is sophisticated. High-precision printers use six lasers in parallel to build each watch case in more than nine hundred layers.
Before printing even begins, Apple must convert the recycled titanium into powder form, carefully controlling oxygen levels to prevent hazards when the lasers start. That kind of materials science was crucial in making the process both safe and scalable.
This innovation also extends beyond watches. Apple said the same recycled titanium powder and 3D printing methods were used to manufacture the titanium casing around the USB-C port of the new iPhone Air.
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