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Global consumer electronics company Apple has introduced the new iPhone Air and Apple Watch Series 11 using additively manufactured components.
On the iPhone Air, the USB-C port is produced through 3D printing. Apple says the method makes the connector thinner and stronger while using 33% less material than conventional forging. The change supports the device’s 5.6-mm profile, the slimmest iPhone to date, and reflects Apple’s effort to cut waste in production.
Meanwhile, the Apple Watch Series 11 is incorporating 3D printing for its titanium cases, which Apple reports consume about 50% less raw material than the previous process. Preorders have begun for Apple Watch Series 11 with availability from September 19, while iPhone Air preorders begin today with prices beginning at $399 and $999 respectively.
Both devices are tied to Apple’s 2030 strategy, which aims for carbon neutrality across its footprint by the end of the decade. Alongside recycled cobalt in batteries and recycled titanium in frames, 3D printing is presented as a way to combine design innovation with reduced environmental impact.
“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.
The “all-new” iPhone Air and Watch Series 11
Beyond the manufacturing shift, the iPhone Air introduces a thinner build with a titanium frame and Ceramic Shield 2 front cover, which Apple says improves durability. It features a 6.5-inch Super Retina XDR display with an adaptive refresh rate up to 120 Hz and peak brightness of 3,000 nits.
An Action button and Camera Control shortcut provide quick access to functions, while inside the phone runs on the A19 Pro chip paired with the N1 networking chip and C1X modem. Apple says the new architecture supports Wi-Fi 7, Bluetooth 6, and faster cellular performance, while also improving energy efficiency.
A redesigned internal layout allows more battery space, complemented by Adaptive Power Mode in iOS 26, which manages energy use based on habits. Meanwhile, the Apple Watch Series 11 highlights health functions alongside its new case production.
A hypertension notification feature monitors optical heart sensor data over 30-day periods and alerts users if patterns suggest consistently elevated blood pressure. Apple says the tool was trained on data from more than 100,000 participants and validated in a 2,000-person clinical study, although it does not replace medical diagnosis.
The watch also introduces a sleep score that evaluates duration, consistency, and time in different sleep stages to provide a nightly quality rating. According to Apple, the scoring system draws on guidance from leading sleep research bodies and was tested with millions of nights of data.
Battery life extends to 24 hours, with fast charging that provides about eight hours of use in 15 minutes. Aluminum models use Ion-X strengthened glass with a ceramic coating for improved scratch resistance, while titanium models retain sapphire crystal.
The Series 11 also supports 5G with redesigned antennas to boost performance when used without an iPhone nearby. It runs on watchOS 26, which brings new workout tools, redesigned watch faces, gesture controls, and Live Translation when paired with a supported iPhone.
Rise in 3D printed consumer electronics
Since the launch, industry commentators have highlighted the shift on LinkedIn. Additive manufacturing in consumer electronics has long been discussed but seldom applied at scale.
Apple’s adoption shows 3D printing advancing beyond prototypes, enabling slimmer designs, lighter components, and greater material efficiency than traditional methods. Of particular note, Rajeev Kulkarni, Chief Strategy Officer (CSO) of Axtra3D writes on LinkedIn, “This is a signal worth paying attention to.”
Beyond Apple, OPPO’s new Find N5 foldable smartphone introduced a Titanium Flexion Hinge produced with BLT’s metal 3D printing. Using aerospace-grade titanium alloy, the hinge was reduced in thickness from 0.3 mm to 0.15 mm while improving rigidity by 36%.
Compared with its predecessor, the hinge is 26% smaller yet stronger, with the hinge cover and wing plate also additively manufactured from Grade 5 titanium. The process allowed for precise internal reinforcements not possible with machining or casting. Load-bearing components used ultra-high-strength steel, and the device earned TÜV Rheinland certification for durability under extended folding cycles.
On a smaller scale, London-based startup Kibu launched its sustainable children’s headphones in partnership with Batch.Works and Morrama, using 3D printing and recycled PLA derived from agricultural packaging waste.
Over 70% of the components are said to be recyclable, and returned units were repurposed into new headphones to promote a circular economy. The design allows children to assemble, repair, and customize their own devices, encouraging hands-on learning and responsibility.
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Featured image shows Apple’s iPhone Air color lineup. Photo via Apple.
