Apple is taking a deeper dive into additive manufacturing, with plans to use 3D‑printed aluminum in future versions of its iconic devices. According to Bloomberg journalist Mark Gurman’s latest Power On newsletter, the company’s manufacturing design and operations teams are exploring ways to print aluminum components for future iPhone and Apple Watch models — a move that could reshape how Apple builds its hardware.
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This development builds on Apple’s earlier use of metal 3D printing. The tech giant previously used 3D‑printed titanium in products like the Apple Watch Ultra 3 and Apple Watch Series 11, leveraging 100 % recycled aerospace‑grade titanium powder to reduce waste and improve sustainability. The iPhone Air also benefited from this technology with a titanium USB‑C port that is thinner and stronger than parts produced by traditional machining.
The next step Apple is considering involves applying additive manufacturing to aluminum, a lighter and widely used metal in its product lineup. The initial focus is expected to be on watch casings, where 3D printing could boost production efficiency and reduce material waste. If successful, the process could eventually extend to iPhone enclosures, potentially lowering production costs and influencing future pricing strategies.
Apple’s newly introduced MacBook Neo already uses a conventional but more material‑efficient aluminum manufacturing process, enabling a competitive $599 starting price. This shows how Apple is experimenting with both design and production innovations to optimize costs ahead of broader technology shifts.
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Beyond potential cost savings, 3D printing could unlock new design possibilities and sustainability gains. It may also enable Apple to introduce refreshed aesthetics and material efficiencies across its product lines, including updated colors for the iMac later this year.