Here's How Apple Uses 3D Printing for Apple Watch and iPhone Air

[MacRumors]

Apple today highlighted its use of 3D-printed titanium in a trio of devices, the step-by-step process involved, and a few benefits of the technology.

The titanium case on Apple Watch Ultra 3 models, the titanium case on higher-end Apple Watch Series 11 models, and the USB-C port on the iPhone Air are all 3D printed with 100% recycled aerospace-grade titanium powder, according to Apple.

3D printing involves creating an object layer by layer with powdered metal, until it is as close to the final shape needed as possible. It is an additive process, meaning that materials are only used as needed, whereas conventional forging is a more wasteful process that involves taking a solid block of metal and shaving it down into a desired part.

Apple says its use of 3D printing enables Apple Watch Ultra 3 and titanium Apple Watch Series 11 cases to use just half the raw material compared to the equivalent previous-generation models. In total, Apple estimates that more than 400 metric tons of raw titanium will be saved this year alone thanks to this new process.

Apple is aiming to achieve carbon neutrality across its entire footprint by 2030, and 3D printing helps it get one step closer to that goal.

"A 50 percent drop is a massive achievement — you're getting two watches out of the same amount of material used for one," said Sarah Chandler, Apple's Vice President of Environment and Supply Chain Innovation, in the press release.

In addition to the environmental benefits, Apple said 3D printing improves waterproofing for the antenna housing in cellular Apple Watch models, as it provides better bonding between the metal case and the thin plastic strip for antenna signals.

Apple previously said the iPhone Air's 3D-printed USB-C port offers three benefits compared to one made with a conventional forging process: it is thinner, stronger, and uses 33% less material to be more environmentally friendly.

Apple goes on to detail its step-by-step process for 3D printing titanium Apple Watch cases. First, raw titanium is atomized into powder. Then, a machine with lasers uses that powder to build a set of cases layer by layer. Next, excess powder is removed from the cases. After the cases are separated, they are put through a final quality check.

The full article on Apple's website is a worthwhile read if you are interested in learning more.

Article Link: Here's How Apple Uses 3D Printing for Apple Watch and iPhone Air

 

[turbineseaplane]

Apple is aiming to achieve carbon neutrality across its entire footprint by 2030

Just a note that carbon "neutrality" isn't what it sounds like.

They have to purchase loads of carbon credits to offset their carbon output to make the claim of "neutrality".

There are many things one can read about this if interested.
Begin your searches with "Apple" and "greenwashing" and go from there.

 

[varsity]

Apple is ignoring the massive energy cost of producing titanium powder and instead focusing on 3D printing efficiency and renewable electricity usage. This is a selective framing that helps meet sustainability targets without meaningfully reducing total energy consumption.

Recycled or not there’s still massive costs to produce titanium powder. Should we not draw criticism for information not disclosed (recycled smelting costs and powdering process) or trust blindly that Apple is being 100% honest with this claim?

 

[AppleTLDR]

Apple is ignoring the massive energy cost of producing titanium powder and instead focusing on 3D printing efficiency and renewable electricity usage. This is a selective framing that helps meet sustainability targets without meaningfully reducing total energy consumption.

It feels like you haven’t read the press release:

“100 percent recycled aerospace-grade titanium powder”

Apple sources the powder from industrial titanium waste streams. Some reclaimed from the aerospace industry and some is in house scrap.

But even if they weren’t using recycled titanium, producing a single watch case using this method uses 50% less titanium. They’re able to make twice as many cases with the same amount of material. So unless Apple Watch sales doubled, which is unlikely, there’s up to a 50% energy saving even if they were using raw titanium. Which they aren’t.

 

[xmach]

Apple is ignoring the massive energy cost of producing titanium powder and instead focusing on 3D printing efficiency and renewable electricity usage. This is a selective framing that helps meet sustainability targets without meaningfully reducing total energy consumption.

They're now using 50% as much raw material (titanium). Do you have any idea how much energy it costs to extract titanium from the Earth?

This is a significant achievement. Apple should be proud, and is right to to publicize this advance.

 

[I7guy]

Just a note that carbon "neutrality" isn't what it sounds like.

They have to purchase loads of carbon credits to offset their carbon output to make the claim of "neutrality".

There are many things one can read about this if interested.
Begin your searches with "Apple" and "greenwashing" and go from there.

Can’t blame Apple for a system already in place.

 

[neuropsychguy]

Apple is ignoring the massive energy cost of producing titanium powder and instead focusing on 3D printing efficiency and renewable electricity usage. This is a selective framing that helps meet sustainability targets without meaningfully reducing total energy consumption.

Recycled or not there’s still massive costs to produce titanium powder. Should we not draw criticism for information not disclosed (recycled smelting costs and powdering process) or trust blindly that Apple is being 100% honest with this claim?

The big energy cost for titanium is extracting/making the metal (e.g., mining, transport, and refining), not shaping it. Apple is using recycled titanium powder and says the new process uses 50% less titanium for those cases. There are costs for powder production but using recycled titanium should substantially reduce start to end energy costs for Apple. If you’ve got data showing the total energy or CO₂ is unchanged, it’d be good to see it -- otherwise you're just guessing about total energy consumption and are doing what you are criticizing Apple for doing (selectively framing).

 

[the future]

Also, can we just acknowledge that it is pretty awesome that 3D-printing is a thing now on such a massive industrial scale? It blows my mind a little that the Ultra 3 on my wrist right now was indeed 3D-printed.

 

[Octavius8]

“…and the users pay 40% less for that reason and also for the same tech as 3 years ago…”.

 

[Octavius8]

So, titanium is bonded by lasers?. Heat?

 

[mansplains]

So, titanium is bonded by lasers?. Heat?

It’s a process called Laser Powder Bed Fusion, LPBF. The high powered laser(s) selectively melt and fuse metal powders fully. I worked in the field of industrial metal 3D printing for a few years, it’s fascinating.

I’ve attached a short clip of a laser striking the powder bed, this is one layer of the print. There’s an arm moving to the left, called a recoater. It coats the build area with a new thin layer of material, pulled from the right, excess powder dumps in the left.

With layer heights in microns, it can be thousands of layers depending on your build. Sintering is a similar additive manufacturing process.

Feel free to DM me for more info.

 

[JMStearnsX2]

I think the 50% less claim might be a bit disingenuous. It's the same size case when finished, whether 3D printed or milled right? Are they making it thinner when 3D printed? Am I to believe that Apple throws away the removed material when metal is milled, is that where the 50% less material comes from?

Genuine questions here.

 

[neuropsychguy]

I think the 50% less claim might be a bit disingenuous. It's the same size case when finished, whether 3D printed or milled right? Are they making it thinner when 3D printed? Am I to believe that Apple throws away the removed material when metal is milled, is that where the 50% less material comes from?

Genuine questions here.

Think of it this way. Apple buys titanium -- either chunks of it to machine or powdered. With the traditional machining process, metal is shaved off (subtractive process) to get to the end product. With the 3D printing approach, it's additive. Apple uses closer to what it needs for the final product. This means Apple can get two watches out of the same amount of processed titanium compared to the old approach. The excess titanium with the machining process isn't thrown away but it would need to go back and be reprocessed (recycled). The 3D approach is much more efficient with the material.

 

[richinaus]

I do love reading all the negativity and trying to find fault in everything.
At least Apple are proactively doing something and also create products that last which means less upgrades.

No business that makes things is going to be 100% green, net neutral etc. I dont believe any of it, but can recognise that Apple appear to be a lot better than 99% of the rest.
Look to fast fashion, plastics in the supermarket and everywhere else and the mountains of cheap crap if you want to get angry about something.