March 9, 2026, 1:31 pm | Read time: 2 minutes
Apple is expanding the use of 3D printing in its production. In the future, not only smartwatches but possibly also iPhones could be more extensively manufactured with 3D-printed components. The focus is apparently on aluminum as a material for housing components.
As early as November 2025, Apple announced that it would use 3D printing for the cases of the Apple Watch Ultra 3 and the Apple Watch Series 11. At that time, it was about titanium cases, which are printed layer by layer and not milled from a solid block. This allows Apple to use the material more efficiently and reduce production waste. According to its own statements, the company aimed to save more than 400 tons of raw titanium with this process in 2025. According to Mark Gurman’s “Power On” newsletter for the Bloomberg news portal, Apple Watches and even iPhones will be printed with aluminum in the future.
Differences Between Titanium and Aluminum
Titanium and aluminum differ significantly. Titanium is very strong, corrosion-resistant, and more scratch-resistant. It is considered a high-quality material but is expensive and complex to process. Aluminum is lighter and significantly cheaper. However, it is less stable and more prone to wear and tear.
To achieve comparable stability, aluminum components often need to be constructed a bit thicker. In mass production, however, aluminum is easier to handle and more economical. Additionally, coloring aluminum cases through hard anodizing is possible. More complex methods are necessary for titanium.
Also of interest: iPhone 17e Is Here! Here’s Where Apple Is Saving
Possible Implications for Buyers
A reason for the increased use of aluminum could be lower costs and better scalability. While titanium is mainly suitable for high-priced models like the Ultra series, aluminum could make 3D printing economical for larger quantities like the iPhone. Lower material costs could theoretically allow for stable prices or more attractive entry-level models. Additionally, 3D printing enables more complex internal structures, which could favor thinner or lighter devices in the long term.
However, there are also disadvantages. Aluminum is less robust than titanium and can show visible wear more quickly. As a lightweight metal with high thermal conductivity, it is technically challenging in 3D printing. Without precise temperature control, components can warp or internal stresses can develop in the material. If quality differences occur, it can affect durability or finish. Moreover, it is unclear whether Apple will actually pass on potential cost advantages to buyers.