These new manufacturing processes are good for Apple and the environment

Apple hardware design leader Molly Anderson said the company started from scratch when it came to the manufacturing process of the new macbook neoresulting in much more efficient use of materials.

The company is also reportedly looking to adopt an extremely challenging manufacturing technique for the aluminum chassis of future iPhone and Apple Watch models…

Apple had already touted the environmental credentials of its latest laptop, claiming it had set a new record for recycled materials.

It features 60 percent recycled content, the highest percentage of any Apple product. This includes 90 percent recycled aluminum overall and 100 percent recycled cobalt in the battery.

New machining process for the MacBook Neo

The company also referenced a new manufacturing process, but did not provide details at the time.

The cabinet is manufactured with a forming process that saves materials and uses 50 percent less aluminum compared to traditional machining methods.

For previous MacBooks, Apple had started with a rectangular piece of aluminum and machined it to shape. This resulted in significant unused cuts. For the MacBook Neo, however, Anderson explained. that the company was able to drastically reduce the amount of unused aluminum.

“We start with an extrusion, flatten it, and then form it with heat and pressure to get as close to the shape of the final product as possible,” Anderson explained. “Then we fine-tune the machine to create the profile.” According to Anderson this (…) reduced the amount of material used by half.

Reducing material waste is good for Apple’s margins, but also for the environment. While the company will of course recycle scraps where possible, reducing their number is a more efficient approach. Anderson added that it also reduced the amount of machining time involved, which likely also reduces energy consumption.

3D printing of iPhone and Apple Watch chassis

Apple first started using 3D printing for the titanium chassis of the Apple Watch Ultra 3. The company said at the time that this allowed it to use 100% recycled titanium powder and was a more efficient use of the material.

TO Bloomberg The report says that the company is now working on ways to 3D printed aluminum for the chassis of future iPhone and Apple Watch models.

Aluminum 3D printing is a notoriously challenging process for several reasons. The high reflectivity and thermal conductivity make the material difficult to shape with a laser, and extreme precision is needed to avoid the risk of microscopic internal voids that can reduce the strength of the finished product.

For these reasons, it is typically only used in applications such as aviation and automotive manufacturing, where weight savings and large material volumes can justify the complexity of the manufacturing process. Apple successfully implementing it into mass production of small consumer electronics would be a significant achievement.

Victories for Apple and the environment

Being able to highlight the environmental credentials of new products while saving money on their manufacturing is the ultimate win-win for Apple’s bottom line and the environment.

Photo by Opt for lasers in unpack