TECHNOLOGY
The iPhone Air's Secret: A Tiny but Mighty USB-C Port
USAFri Sep 12 2025
The iPhone Air, unveiled at the recent Apple event, has everyone talking about its super slim design. But how did Apple make it so thin while keeping a functional USB-C port? The answer lies in a new way of making things.
Apple used a special method called 3D printing to create the USB-C port. Instead of using traditional methods, they printed the port layer by layer with titanium powder. This makes the port not only thinner but also stronger and more eco-friendly.
The idea for this innovation came from the M4 iPad Pro, which was Apple's thinnest device so far. People noticed that the USB-C port on the iPad Pro was almost as thick as the device itself. This showed that the port was a big hurdle in making devices even thinner.
The iPhone Air is 5. 6mm thick, which is not as thin as the M4 iPad Pro, but it's still a significant achievement. The 3D-printed titanium port is 33% lighter and uses less material, making it more sustainable.
Apple has used similar techniques in other products, like the Apple Watch Ultra 3 and the higher-end Apple Watch Series 11. These watches also benefit from the reduced material usage while maintaining their strength.
Despite the advanced manufacturing process, the USB-C port on the iPhone Air still has the same data transfer speed as other iPhone models. This means that while the port is physically different, its performance remains the same.
The iPhone Air will be available for pre-order on Friday at 5 a. m. PT, with the official launch scheduled for September 19. This new model shows how Apple is always looking for ways to push the limits of design and technology.
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questions
How does the 3D-printed titanium USB-C port affect the overall durability and bending resistance of the iPhone Air?
Is the iPhone Air's USB-C port design a secret alliance with a titanium mining company?
How does the 3D-printed titanium USB-C port in the iPhone Air compare to traditional ports in terms of longevity and reliability?
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