Apple exploring 3D-printed aluminum chassis for future iPhone and Apple Watch

Apple is reportedly exploring the use of 3D-printed aluminum to manufacture parts for future iPhone and Apple Watch models, a move that could make production more efficient and unlock new design possibilities.

According to Bloomberg’s Mark Gurman, Apple’s manufacturing design team is working with its operations department to develop ways of 3D-printing aluminum components. Writing in his weekly Power On newsletter, Gurman said the technology could initially be used for Apple Watch casings and may eventually extend to iPhone enclosures.

The shift could allow Apple to produce certain components more efficiently while also enabling design features that are difficult or impossible with traditional forging methods. Gurman notes that 3D printing can create textures in areas that were previously inaccessible during the manufacturing process.

One example involves the Apple Watch antenna housing in cellular models. Within the case, cellular versions include a split filled with plastic to allow the antenna to function properly. By 3D-printing a specific texture on the inner metal surface, Apple was able to improve the bonding between the plastic and the metal, helping enhance waterproofing around the antenna housing.

Apple has already been using 3D printing in several recent products. The iPhone Air uses the technology to manufacture a thinner USB-C port, while the Apple Watch Ultra 3 introduced a new 3D-printing process for its titanium shell that reduces raw material use and lowers production costs. Apple also uses 3D printing for the titanium version of the Apple Watch Series 11, relying on 100% recycled titanium powder during manufacturing.