Apple’s new press release gives a clear look at how the company now uses 3D printing to build the Apple Watch Series 11 and Apple Watch Ultra 3. Both models rely on 100 percent recycled aerospace-grade titanium powder.
Apple says this level of recycled material use was not considered possible at scale, yet the company pushed ahead to make it work. The result is a cleaner process that reduces waste while keeping the familiar strength and finish you expect from an Apple Watch.
As Apple details, every team worked together to perfect the new method. The polished mirror finish on Series 11 needed to stay sharp, and Ultra 3 needed to keep its tough and lightweight shape for long hikes and daily use.
At the same time, both watches had to stay environmentally responsible. According to Sarah Chandler, who oversees Environment and Supply Chain Innovation, using this approach cuts raw titanium use by half.
How Apple Uses 3D Printing
Apple explains that additive manufacturing prints layer by layer to reach the final shape. Traditional machining removes material, so a large amount of titanium gets wasted. By switching to 3D printing, Apple uses only the material required. This shift saves more than 400 metric tons of raw titanium in 2025 and reduces the material load for both Series 11 and Ultra 3 by 50 percent. Chandler says this drop lets Apple get two watches from the amount of material that previously produced one.
The company ties these changes to its Apple 2030 plan. It highlights that all electricity used for Apple Watch production already comes from renewable sources. The new process also helps improve waterproofing in the antenna housing on cellular models, giving Series 11 and Ultra 3 a stronger design.
Beyond the Watch
Apple also says the same technique made a key upgrade possible for the new iPhone Air. The thin 5.6 mm chassis includes a USB-C port built with a titanium enclosure that uses the same recycled powder. This flexibility allowed Apple to design a port that stays slim but strong.
All of this shows how 3D printing shapes Apple’s current hardware and sets the direction for future products.
