Apple will use 3D printing for some Apple Watches. Jeenah Moon/Bloomberg via Getty Images
According to insiders, Apple Inc. is testing the use of 3D printers to produce the steel case that will be used for some of its upcoming smartwatches, heralding a big change in the way the company makes products.
The technique would eliminate the need to cut large sheets of metal into the shape of the product. This would reduce the time it takes to build equipment while also being kind to the environment by using fewer materials, according to people, who declined to be named as the plan is private.
The new approach has the potential to streamline Apple’s supply chain and spark broader change. If work with Apple Watches goes according to plan, the tech giant will look to expand the process to other products over the next few years, the people said. A spokeswoman for the Cupertino, California-based company declined to comment.
So far, Apple has used a more conventional approach to manufacturing for its stainless steel watches, which make up about 10% of the line’s total units. A process called forging involves shaping blocks of material into a smaller block of metal roughly the size of the device. A CNC (Computer Numerical Control) machine is then used to cut into the metal to create the exact design and buttonholes.
The new technique uses a type of 3D printing called binder jetting to create the general outline of the device close to its actual size, or what in manufacturing is known as the “near-net shape.” The print is made from a powdered substance that then goes through a process called sintering. This involves using heat and pressure to stamp the material into something that feels like traditional steel. The exact design and cutouts are then milled as in the previous process.
The news gave 3D printing companies like 3D Systems Corp. and Stratasys Ltd. Boost. 3D Systems shares rose as much as 10%, while Stratasys gained 6.9%. Stocks later eat into those gains. Apple was up 1.8% to $187.46 as of 2:48 p.m. in New York.
Apple and its suppliers have been quietly advancing the technology for at least three years. For the past few months, they’ve been testing the steel-case process for the Apple Watch Series 9, which is due to be unveiled on September 12. The smartwatch will get a performance upgrade and new case colors, although visually appealing will remain largely the same, Bloomberg has reported.
There’s no guarantee that the first consumer shipments of the new steel Apple Watches will be made using the revised manufacturing technique, but the test run shows that the company is serious about this approach. Apple plans to apply the process to its titanium Ultra watch as well, but such a switch is not planned before 2024.
The approach benefits the environment by using roughly the same amount of metal as is needed to manufacture the device cases. In a further step towards sustainability, Apple plans to use new materials to replace leather in some of its new iPhone cases and other accessories, other people familiar with the matter have said.
The 3D printing work is being led by Apple’s manufacturing design team, which is led by Rob York, a company vice president, and reports to operations manager Sabih Khan. The move to 3D-printed watch cases has been a costly endeavor for Apple and its suppliers, but over time it should simplify production and potentially reduce costs. Currently, the cost per watch case with the new method is the same as the previous method.
Work is still in the early stages and will initially be reserved for lower volume products. Most Apple Watch cases are made of aluminum and not stainless steel. The company has made no progress in mass-producing 3D-printed cases from the material, which is also used for Macs and iPads, as well as lower-end iPhones. However, the company is discussing making 3D printed materials such as steel and titanium available for more devices.
The initiative is one of the first instances of binder jetting being used to mass produce a metal part in high volume. Making the Apple Watch the test case for new technologies is part of a pattern for the company. For example, Apple added steel frames to the iPhone two years after it appeared on the original Apple Watch. And this year’s high-end iPhones will use Ultra Titanium a year after the material on the Apple Watch was introduced.
— With the support of Debby Wu
