Reports in 2023 revealed that Apple had begun using metal 3D printing (binder jetting) for certain Apple Watch components, such as the steel chassis. However, the company had already been quietly leveraging additive manufacturing for several years. One thing is certain: like most major tech companies, Apple relies on 3D printing to support the rapid prototyping of device components. These range from enclosures to internal parts, within its manufacturing facilities.
The latest gadget from the company is the iPhone Air, a new iPhone that features an impossibly thin and light design, said to be more durable than any previous model.
“The all-new iPhone Air is so powerful, yet impossibly thin and light, that you really have to hold it to believe it’s real. This huge leap in design and engineering is only made possible through Apple innovation, especially Apple silicon,” said John Ternus, Apple’s senior vice president of Hardware Engineering. “iPhone Air is a brand-new member of the iPhone family that delivers advanced features our users will love, like pro performance, a versatile 48MP Fusion camera system, our innovative Center Stage front camera, and great all-day battery life — all in a breakthrough design that feels like you’re holding the future.”
A titanium USB-C port made with 3D printing
At the manufacturing level, the company used metal 3D printing to achieve its ambitious plan to be carbon neutral across its entire footprint by the end of this decade.
iPhone Air is made with 35 percent recycled content, including 80 percent recycled titanium, the highest ever for an iPhone, and 100 percent recycled cobalt in the battery. The company says a new titanium USB-C port is 3D-printed to be thinner and stronger. It fits into the slim design while using 33 percent less material than a conventional forging process.
A tiny titanium 3D printed part, some might say. But it counts for an entire industry and consumer tech companies looking to scale production with metal 3D printing.
Finishes and availability
iPhone Air will be available in four gorgeous finishes: space black, cloud white, light gold, and sky blue. Pre-orders begin Friday, September 12, with availability beginning Friday, September 19.
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