Apple Leak: 3D-Printed Aluminum Coming to Future iPhones and Watches

Apple is quietly testing a new way to build its most popular products. According to Bloomberg’s Mark Gurman, the company is making a major push into 3D-printed aluminum, a move that could eventually change how the iPhone in your pocket is made.

Writing in his latest Power On newsletter, Gurman reveals that Apple’s manufacturing and operations teams are working on 3D-printing aluminum parts to boost efficiency. This isn’t just a lab experiment; it’s a follow-up to the 3D-printed titanium already being used in the Apple Watch Ultra 3.

The goal? Speed and savings. Sources tell Gurman that 3D printing allows Apple to use far less raw metal compared to traditional “subtractive” manufacturing, where a solid block of aluminum is carved down. Initially, this tech is tipped for Apple Watch casings, but the long-term play is to bring 3D-printed enclosures to the iPhone.

We’re already seeing the first signs of this efficiency with the new MacBook Neo. At $799 CAD, the Neo relies on a specialized material-efficient forming process that reportedly saves 50% more aluminum than usual, which is being dubbed as production magic. It allowed Apple to use aluminum instead of cheaper plastic for this MacBook.

New iMacs and the ‘Ultra’ MacBook

Beyond the factory floor, Gurman has laid out the rest of the 2026 Apple roadmap. If you’ve been waiting for a desktop refresh, here is the timeline he’s tracking…

• Mid-2026: New Mac Studio and Mac mini models are expected. Don’t expect a total redesign, though. Gurman says they’ll look the same as before (which is a classic Apple upgrade move).
• Late 2026: A refreshed iMac is coming, and while the internals get a bump, the big news is a brand-new colours.
• End of Year: The ‘one more thing’ for 2026 appears to be a high-end MacBook Ultra. This would be Apple’s first laptop with an OLED touchscreen, possibly sitting in a tier even higher than the current MacBook Pro. And we know that’s going to come with a higher price.

What Apple devices are you looking to upgrade this year?