Apple explores 3D printing for aluminium iPhones and Apple Watches

Apple is reportedly investigating new ways to manufacture parts of its devices using 3D printing technology, a move that could reshape how some of its most popular products are built. According to a report by Bloomberg journalist Mark Gurman, the company is exploring methods to 3D-print aluminium components for future iPhones and Apple Watches.

The potential shift would focus on device enclosures and casings, areas where aluminium is widely used in Apple’s hardware. If implemented at scale, the process could improve manufacturing efficiency and, over time, reduce production costs.

Apple has already experimented with 3D printing in recent product generations. Expanding the technology to aluminium could represent the next stage in the company’s efforts to refine its manufacturing processes while also addressing environmental and design goals.

Apple examines 3D printing for aluminium device parts

The reported initiative centres on developing a manufacturing process that enables aluminium parts to be produced via 3D printing rather than traditional machining methods. Apple currently relies heavily on computer numerical control milling to shape aluminium enclosures, a process that is precise but can generate significant material waste.

By contrast, additive manufacturing techniques build components layer by layer, using only the material needed to form the structure. If Apple successfully adapts this process for aluminium device casings, it could reduce the amount of excess metal removed during production and streamline assembly.

According to the report, the company is particularly interested in applying the method to Apple Watch casings and iPhone frames. These parts must meet strict standards for durability, weight and finish, meaning the technology would need to produce components that match Apple’s current design quality.

Such an approach could also allow Apple’s engineers to experiment with new internal structures or design variations that are difficult to achieve through conventional manufacturing. While the company has not confirmed the development publicly, the exploration suggests Apple is continuing to invest heavily in advanced production technologies.

Previous use of 3D printing in Apple products

Apple has already used 3D printing for certain components of its devices, particularly those made of titanium. For example, both the Apple Watch Ultra 3 and Apple Watch Series 11 reportedly incorporated parts manufactured from 3D-printed, fully recycled titanium.

The company has also applied similar techniques in other hardware elements. In the recently introduced iPhone Air, Apple used 3D printing to produce a titanium USB-C port. The component was described as thinner, stronger and more environmentally friendly than traditional alternatives.

These experiments indicate that Apple has been gradually integrating additive manufacturing into its supply chain rather than introducing it across entire devices at once. By first applying the technology to smaller or specialised components, the company can refine production techniques before expanding them to larger structural parts.

The shift towards recycled materials has also been an important theme in Apple’s recent hardware strategy. Using 3D printing alongside recycled metals allows manufacturers to minimise waste and reduce the environmental impact of large-scale electronics production.

While the current exploration focuses on aluminium rather than titanium, the same sustainability and efficiency goals could apply. Aluminium is one of the most widely used metals in Apple’s hardware, making it a natural candidate for experimentation with new manufacturing methods.

Manufacturing changes could affect pricing and design

If Apple succeeds in adapting 3D printing for aluminium parts, the technology could influence both product pricing and design flexibility. Additive manufacturing has the potential to simplify production steps and reduce the amount of raw material required to build each device.

Lower manufacturing costs do not always translate directly into cheaper consumer prices, but they can help companies offer more competitively priced products. Observers have pointed to Apple’s recent hardware announcements as an example of how manufacturing efficiencies can help make devices more accessible.

The company’s newly introduced MacBook Neo demonstrates this approach. Apple used a revised production technique for its aluminium chassis that reduces the amount of metal required during manufacturing. That change helped the company introduce the entry-level laptop with a starting price of US$599.

Future iPhones or Apple Watches produced using 3D-printed aluminium could benefit from similar efficiencies. The technology might also give Apple’s designers greater freedom to experiment with new structural layouts or lighter internal frames without compromising strength.

Alongside manufacturing changes, Apple is also expected to refresh the visual design of some of its devices. Gurman reported that the company is preparing to unveil an updated version of the iMac later this year that will feature a “refreshed colour palette”.

Although the report focuses mainly on future production techniques, the combination of new manufacturing processes and updated design elements suggests Apple is continuing to evolve how its hardware is both made and presented.

For now, the company’s work with 3D-printed aluminium remains exploratory. However, if Apple decides to deploy the technology across major product lines, it could mark one of the most significant shifts in its hardware manufacturing strategy in years.