Apple has adopted additive manufacturing (or 3D printing) for making chassis for Apple Watches as well as USB-C port receptacles for the ultra-thin iPhone Air. The company is printing these components using titanium powder obtained from recycling, thus greatly reducing usage of materials while achieving its products' signature great looks and structural strength. This is the first time that Apple has applied additive manufacturing for a mass-market device.
To build chassis for Apple Watch Ultra 3, Apple Watch 11 titanium, and the USB-C receptacle of the iPhone Air, Apple uses a special powder-based laser process that fuses together fine titanium grains — each around 50 micrometers across and refined to keep oxygen levels low to avoid explosions during heating — layer by layer using a laser. To produce one watch chassis, the company says a metal 3D printer with one galvanometer housing six lasers makes 900 passes to craft numerous layers that are exactly 60 microns thick.
