Apple has officially announced again: two models of Apple Watch cases are made of LPBF titanium alloy via 3D printing

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November 20, 2025 Applications 12177

Apple Reiterates Announcement: Certain Apple Watch Models Feature Fully 3D-Printed Titanium Alloy Cases Using LPBF Technology

Following its initial announcement at the new product launch event, Apple has once again officially confirmed that certain models of the Apple Watch feature cases entirely made from 3D-printed titanium alloy, utilizing LPBF (Laser Powder Bed Fusion) metal 3D printing technology.

In October 2025, a foreign tech enthusiast disassembled the Apple iPhone Air and discovered that its USB-C port was made from 3D-printed titanium alloy. Subsequently, they also disassembled the new Apple Watch Ultra 3 and found that its case was also metal 3D-printed. In November 2025, the same individual purchased a new Apple Watch Ultra 3, disassembled it, and placed the watch case under a DSX2000 digital microscope to capture high-definition photos.

The microscopic examination revealed distinct layered 3D printing patterns, with relatively smooth and even lines. These are likely the cases for the officially promoted Apple Watch Ultra 3 and the high-end model of the Apple Watch Series 11, which are stated to be 3D-printed using 100% recycled titanium.

An Apple supply chain expert in China indicated that these 3D-printed titanium alloy cases are produced by metal manufacturers in China, likely including companies such as BLT (Bright Laser Technologies).

On November 18, 2025, Apple's official website published an article titled "Mapping the future with 3D-printed titanium Apple Watch cases." It mentioned:

All Apple Watch Ultra 3 and titanium Apple Watch Series 11 cases are manufactured using a 3D printing process with 100% aerospace-grade recycled titanium powder—a technology previously thought impossible to scale for mass production.

Every team at Apple came together around a shared, ambitious vision. The polished, mirror-like finish of the Series 11 had to be flawless. The Ultra 3 had to maintain its durability and lightweight form factor for everyday use and adventure. Both watches also had to be better for the environment without compromising performance, using equivalent or superior raw materials.

Over the past decade, Apple has been experimenting with 3D printing technology, a period during which the industry has also developed rapidly.

"We are deeply committed to systemic change. We don't make changes just to check a box—we make changes to establish how the entire system should work moving forward." — Sarah Chandler, Apple's Vice President of Environment and Supply Chain Innovation.

The article included images labeled: "△ Laser sintering metal powder" and "△ Metal 3D-printed Apple Watch case," sourced from Apple.

It described the process: "These are 3D printers busy manufacturing titanium cases for the Apple Watch Ultra 3 and Series 11. Each machine is equipped with a scanner system containing six lasers that operate simultaneously, printing layer by layer over 900 times to complete a single case."

Before printing begins, the titanium raw material must be atomized into titanium powder. This process requires precise adjustment of oxygen content to mitigate titanium's tendency to be explosive when heated.

"The powder diameter must be controlled to 50 microns, equivalent to very fine sand grains," explained Manjunathaiah. "When laser interacts with this powder, the reaction differs significantly based on oxygen presence. So, we absolutely must find ways to maintain low oxygen levels."

"We need to control the thickness of each material layer to 60 microns, which requires very fine scraping and pressing of the titanium metal powder."

The disassembler also performed a scratch test on the 3D-printed titanium case using a hard object to assess its scratch resistance. "Surprisingly, thanks to the anodizing process, the 3D-printed Ultra 3's performance in scratch resistance does not lag behind the traditionally CNC-machined Ultra 2; both began showing scratches only at Level 6 on the Mohs scale. In contrast, the Ultra 1, which lacked anodizing, started showing scratches at Level 5."

Reference link from Apple's website:
https://www.apple.com.cn/newsroom/2025/11/mapping-the-future-with-3d-printed-titanium-apple-watch-cases/

Beyond the watch, the fact that the USB-C port on the eSIM-only iPhone Air is also 3D-printed titanium alloy has actually garnered even more attention from users and the industry.