Titanium 3D Printing in 2025：the Next Big Thing in Smartphone Design?
On February 13, 2025, OPPO officially revealed the core technological advancements behind its OPPO Find N5, the world’s thinnest folding flagship, which measures just 8.93mm at its thinnest point.
Featuring a new-generation “Sky Dome” architecture and a titanium alloy Sky Dome hinge, the OPPO Find N5 incorporates state-of-the-art materials and design for a next-level folding experience.
The advanced aerospace-grade metal 3D printing technology from Xi'an Bright Laser Technologies, played a key role in manufacturing the critical structural components of the Sky Dome hinge — the wing plates and the outer rotating axis frame. This partnership enabled OPPO to create a lighter, thinner, and stronger foldable structure.
Over the course of more than a year of joint research and development between Platertech and OPPO, the team fully leveraged the advantages of metal 3D printing, pushing past traditional manufacturing limits. They achieved a breakthrough with 28 precision steps, enabling the production of 300 ultra-thin titanium alloy components per batch within 25 hours.
This process shrank the smallest commercial product scale of 3D printed titanium alloys from 0.3mm to 0.15mm. At the same time, the overall rigidity of the hinge increased by 36%, its strength rose by 120%, and its resistance to impact improved by 100%, ensuring the foldable screen smartphone maintains exceptional durability without compromising its slim design.
The production process of titanium alloy 3D printed hinges can be divided into three main stages:
Printing and Forming: Using Laser Powder Bed Fusion (LPBF) technology, titanium alloy powder is sintered layer by layer at a high temperature of 3500°C to achieve high-precision, integrated manufacturing of complex geometries (such as wing plates).
Post-Processing: This includes 28 steps such as support removal, heat treatment, and precision polishing. Among these, polishing and grinding are the most challenging, requiring high-precision equipment and processes to ensure a surface roughness of ≤0.8μm, meeting the strict requirements for mobile phone structural components.
Assembly and Testing: The hinge components undergo 500,000 fold cycles, drop impact tests, and waterproof certification to ensure their reliability over long-term use.
The Growing Appeal of Titanium Metal 3D Printing in Smartphones
In recent years, titanium metal 3D printing has emerged as a technology that many leading smartphone brands are eager to embrace.
From Apple and Huawei to OPPO and Honor, reports suggest that titanium metal 3D printing may soon become a major part of the next generation of smartphone manufacturing.
This raises the question: what makes titanium metal 3D printing so attractive, and will it lead to a boom in the smartphone industry by 2025?
The “Allure” of Titanium Metal 3D Printing
Titanium alloy, often referred to as “aviation alloy” for its impressive strength, lightweight, and corrosion resistance, has long been favored in high-end manufacturing.
In the realm of smartphones, these properties offer distinct advantages. For foldable smartphones, the hinge is a crucial component that must endure frequent folding and unfolding, requiring high strength and durability. Titanium alloy 3D printing technology has perfectly solved this challenge.
Titanium alloy hinges produced with 3D printing are not only 150% stronger than traditional materials but also contribute to a lighter and more reliable folding mechanism.
Additionally, in phone frames, titanium’s lightweight characteristics allow manufacturers to reduce weight without compromising strength or durability, resulting in better overall performance and user experience.
2. Cost “Reversal”
Previously, titanium metal 3D printing was prohibitively expensive, with the cost of a single axle cap reaching approximately 95 yuan. This high cost deterred many smartphone manufacturers from adopting the technology.
However, as the technology has advanced and scaled production has increased, the cost of titanium metal 3D printing has dropped significantly.
Today, the cost of a single axle cap has decreased to under 30 yuan, making titanium metal 3D printing much more feasible for use in smartphones. The key factor in this cost reduction is mass production.
As more smartphone manufacturers embrace this technology, production equipment and processes have been optimized, leading to lower material costs and improved manufacturing efficiency.
This reduction in costs has a positive impact on the entire industry, enabling smartphone makers to enhance product performance and quality without excessive cost increases, and driving the broader adoption of titanium metal 3D printing.
3. “Mature” Technology Path
Currently, the most mature titanium alloy 3D printing technology is Selective Laser Melting (SLM). This technique uses a high-energy laser beam to melt metal powder layer by layer, building up three-dimensional parts.
SLM technology offers high precision, complex geometry capabilities, and high-density output, making it ideal for manufacturing smartphone components with tight tolerances. Several Chinese 3D printing companies, such as Bright Laser Technologies（铂力特）, Farsoon Technologies（华曙高科）, Shining 3D（先临三维）, Jiangsu Hanbon Science and Technology（汉邦激光）, and AVIMETAL AM（中航迈特）, have mastered this technology.
Some of these companies have passed verification from Apple’s contractors, including Foxconn and Luxshare Precision, for 3D printed titanium alloy phone and smartwatch components.
This confirms that the quality and precision meet the required standards, signaling that titanium metal 3D printing is now a mature and reliable technology, paving the way for its widespread use in the smartphone industry.
Smartphone Manufacturers' "Titanium" Momentum
Honor has been a pioneer in applying titanium alloy 3D printing technology. The Magic V2, released in 2023, uses titanium alloy 3D-printed (SLM technology) hinge axle covers, improving material strength by 150%. This innovation achieved both a lighter foldable screen and higher reliability.
In 2024, Honor’s Magic Vs3 continued using this technology, with two consecutive product generations fully validating the mass production capabilities of titanium alloy 3D printing.
Honor's approach has not only enhanced its product competitiveness but also provided valuable insights for the entire industry on applying titanium alloy 3D printing.
Thanks to this technology, the Magic V2 has sold over 1.5 million units, setting a new record for sales of high-end flagship foldable smartphones.
This success owes much to the lightweight design and high reliability enabled by titanium alloy 3D printing, offering consumers a refreshed experience with foldable smartphones.
2. Apple: Poised for Action
As a tech industry giant, Apple’s every move garners significant attention. The company has shown a proactive stance toward 3D printing technology. For instance, some components of the Apple Watch, released in 2023, feature titanium metal parts made with 3D printing, such as the case of the Apple Watch Series 9 produced using stainless steel binder jetting 3D printing, and the digital crown, side button, and other operational buttons of the Apple Watch Ultra made with titanium alloy powder bed laser melting 3D printing.
Notably, renowned Apple analyst Ming-Chi Kuo predicted that Apple might use 3D printing technology in the iPhone’s middle frame and other products. If true, this would undoubtedly have a profound impact on the entire smartphone industry.
Apple has consistently set trends in product design and technological applications, and its exploration of 3D printing technology is likely to spur other smartphone manufacturers to follow suit, driving further technological innovation and development across the industry.
3. OPPO: Bold Innovation
OPPO has taken a bold step in its 2025 folding flagship, the Find N5, adopting 3D printed titanium alloy hinges to achieve the world’s lightest foldable design. The phone has a thickness of just 3.7mm when unfolded, while also supporting high-strength waterproof features. This move demonstrates OPPO’s spirit of innovation and technological breakthrough.
With 3D printed titanium alloy hinges, the OPPO Find N5 is poised to stand out in the foldable smartphone market, offering users an ultra-light, durable foldable experience. The OPPO Find N5, dubbed "the world's thinnest foldable flagship," has a thickness when unfolded of approximately two 1-yuan coins, or around 4mm.
This achievement is largely made possible by the application of 3D printed titanium alloy hinges, which enable the phone to maintain a slim profile while also ensuring sufficient strength and durability.
4. Huawei: Strategic Positioning
Although the application of titanium alloy 3D printing technology in Huawei’s products has not been officially confirmed, rumors suggest that the company may adopt this technology in its foldable smartphones.
As one of the leading smartphone manufacturers globally, Huawei has always been at the forefront of technological research and innovation.
If Huawei indeed incorporates titanium alloy 3D printing into its foldable devices, it would heighten competition in the industry and further drive technological advancements.
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Huawei’s strong R&D capabilities and deep experience in mobile technology would bring fresh ideas and directions for the industry’s evolution.
Should Huawei successfully apply this technology, it could spark a wave of imitation from other manufacturers, accelerating the adoption of titanium alloy 3D printing in the mobile industry.
5. Other Manufacturers: Quietly Following Suit
In addition to the major players mentioned above, companies like Samsung and Xiaomi are quietly adopting titanium alloy 3D printing technology. Samsung’s Galaxy S24 Ultra is set to feature titanium alloy components, while the Xiaomi 14 Ultra Titanium Edition uses titanium alloy injection molding for its middle frame.
Although the application methods and scales may differ among these manufacturers, the trend clearly shows that the smartphone industry is taking titanium alloy 3D printing seriously and actively exploring its potential.
As more companies begin to apply this technology, the development prospects of titanium alloy 3D printing in the smartphone industry will continue to expand. The competition and innovation among manufacturers will push the technology forward, delivering more high-performance, high-quality products to consumers.
The "Titanium" Market Potential
In 2024, China’s foldable smartphone shipments are expected to reach around 9.17 million units, a year-on-year increase of 30.8%. Among these, the Honor Magic Vs3 is a prime example of the use of titanium alloy 3D printing technology. While exact sales figures are not disclosed, estimates suggest sales may be in the hundreds of thousands.
This indicates that while the application of titanium alloy 3D printing in the smartphone market is still relatively small-scale, there is significant room for growth. Despite the limited current scale, the trend for titanium alloy 3D printing in smartphones is clear, with an increasing number of manufacturers exploring and adopting the technology, signaling a promising expansion of the market in the near future.
2. Future Outlook
Looking ahead to 2025, the market outlook appears even more optimistic. OPPO’s Find N5 is already confirmed to feature 3D printed titanium alloy hinges, and with the possibility of Huawei adopting the technology, sales of such devices could reach 2 million units.
If we estimate the titanium alloy printing demand based on a weight of 4g per hinge (post-processing), the required quantity will be quite substantial, considering the pre-processing weight is above 5G and accounting for yield losses.
Moreover, if Apple integrates 3D printed titanium alloy into the iPhone middle frame or heavily incorporates the technology in the Apple Watch, the demand for 3D printing equipment, powder materials, and printing services will soar.
According to CITIC Securities, the market size for titanium alloy 3D printing in the consumer electronics sector could surpass 10 billion yuan, becoming a key driving force for industry innovation.
This prediction is not unfounded—thanks to ongoing technological maturation and further cost reductions, the application of 3D printing in smartphone hinges, middle frames, cases, and other components will become increasingly widespread, and the market scale will continue to expand.
Hidden Risks and Challenges
While titanium alloy 3D printing technology seems promising, the potential risks and challenges should not be overlooked. One key feature of the 3C (computing, communication, consumer electronics) industry is its fast-paced evolution. Not only do products get updated quickly, but changes in technology and supply chains also occur rapidly.
The constant iteration of new materials is a major uncertainty for the growth of 3D printing in the 3C sector. If, in the future, high-strength aluminum or titanium-aluminum alloys become popular, the advantages of titanium alloy 3D printing could diminish.
In the titanium alloy era, 3D printing has an edge due to the difficulty and high cost of traditional processing, as well as low material utilization rates.
However, if new materials become dominant in the market, it is possible that companies like Apple, OPPO, and Honor may reduce their use of titanium alloy 3D printing components after 2026 or 2027 in favor of newer materials.
Despite improving mechanical properties, titanium alloy components can lower heat dissipation efficiency.
Although there are rumors that certain companies are already testing 3D-printed stainless steel heat dissipation components, the emergence of new materials and processes could significantly disrupt the application of 3D printing in the smartphone industry.
2. The Challenges of Keeping Pace with Rapid Industry Evolution
Aside from material uncertainty, the application of 3D printing technology in the 3C sector faces other challenges.
As the 3C industry evolves quickly, changes in materials and processes are also fast-paced. This means that if 3D printing technology cannot keep up with the industry's developments, it could be phased out.
Factories that have heavily invested in 3D printing equipment, costing millions for each machine, face substantial risks.
For example, if a factory installs 100 machines, the investment could exceed 100 million yuan. However, if the material or process changes, these factories could lose major 3C industry clients.
According to industry insiders, as of February 2025, many first and second-tier suppliers in the 3C sector are still hesitant to invest in large-scale 3D printing, fearing that changes in materials could render the advantages of 3D printing obsolete.
For companies like Plitex, which serves various industries, even if the 3C sector's orders decrease, demand from other industries may continue to grow, making the risk relatively smaller.
Future Industry Direction
Despite the risks, the future of titanium alloy 3D printing technology in the smartphone industry still looks promising. The involvement and leadership of global giants like Apple and Huawei could help build a strong titanium alloy 3D printing industry chain in China.
These large companies have a significant impact on technology R&D and market promotion, and their active participation will drive technological innovation and cost reductions across the entire industry chain. In terms of innovation, these giants can invest heavily in research and development of 3D printing technology.
Apple, for instance, has been increasing its R&D investment in 3D printing and collaborating with material suppliers to develop titanium alloy materials suitable for 3D printing to improve performance and print quality.
Their involvement will also drive upgrades in 3D printing equipment, improving production efficiency and product quality.
As for market promotion, the brand influence and market share of these big players will accelerate the adoption of 3D printing technology.
If Apple adopts 3D printing in iPhone middle frames or other products, it will likely inspire other manufacturers to follow suit, thus propelling the entire industry forward.
Furthermore, their participation will foster collaboration and synergy across upstream and downstream companies, creating a healthy industry ecosystem.
2. Diverse Applications Expanding Space
As technology matures and costs continue to drop, the application of 3D printing in smartphone hinges, middle frames, cases, and other components will gradually expand, increasing the market scale.
Beyond the smartphone sector, 3D printing also holds immense potential in other 3C products such as tablets, laptops, and smartwatches. In tablets and laptops, 3D printing can be used to create complex heat dissipation structures, precision internal components, and more, improving product performance and reliability.
In smartwatches, 3D printing can enable customized dial designs, lightweight casing production, and more, catering to consumers' needs for personalized and high-quality products. The application of 3D printing technology is also expanding into industries like aerospace and healthcare.
In aerospace, 3D printing can be used to manufacture complex engine components, lightweight aircraft structures, and more, enhancing performance and safety. In healthcare, 3D printing can produce personalized medical devices, implants, and other items, offering more precise and effective treatment solutions for patients.
As 3D printing technology expands into more fields, its market size will continue to grow, providing strong support for the industry's development.
Conclusion and Reflection
Titanium alloy 3D printing technology in the smartphone industry is filled with both opportunities and challenges. Based on current developments, the active exploration and application by major smartphone manufacturers inject strong momentum into this technology's growth.
By 2025, it’s likely that titanium alloy 3D printing technology will experience explosive growth, with market scale expanding further. However, we must also acknowledge the risks brought by material and process iterations.
In this rapidly evolving industry, only by continuously innovating and progressing can one remain competitive.
How will titanium alloy 3D printing technology develop in the future? Will it achieve large-scale application in the smartphone industry? Share your thoughts.