Canadian additive manufacturing company Mosaic Manufacturing has launched Orion, a purpose-built 3D printing platform for producing custom orthotics in orthotics and prosthetics (O&P) labs and clinics.
The system uses a belt-based 3D printing architecture designed to move patient-specific devices through production sequentially. Automated queue management allows one patient case to follow another, enabling unattended overnight and weekend production. According to Mosaic, a single Orion printer can produce up to 300 pairs of orthotics per month.
Mosaic is positioning Orion as a way for orthotics manufacturers to adopt digital production without replacing their existing clinical workflow. Customers can use the company’s Stryde Software Suite to manage scanning, design and production, or connect the printer to an existing compatible CAD/CAM setup.
“The ask from orthotics manufacturers was clear: they want to move toward digital production, but getting there with the fragmented tools on the market has been painful,” said Mitch Debora, CEO of Mosaic. “They wanted an end-to-end, validated solution they could implement confidently and thrive with — and our team delivered.”
Continuous production for patient-specific orthotics
Orion is designed around the economics of producing individualized devices without proportionally increasing manual labor. Mosaic says a standard reference device can be printed in roughly one hour and 45 minutes, with material costs as low as about US$6 per pair.
Its belt architecture removes the need to clear a conventional print bed between successive jobs. Combined with automated queue management, this is intended to support continuous production of unique devices while reducing operator intervention.
Mosaic also says digital manufacturing can reduce material waste and downstream hand-finishing, allowing technicians to spend more time on complex clinical cases rather than repetitive manufacturing tasks.
Soft and rigid orthotics from one platform
Orion supports two proprietary Mosaic materials developed specifically for custom orthotics: Aero and Align.
Aero is an EVA-like 3D printing material intended for soft-shell, accommodative orthotics. The material was engineered for comfort and resilience while producing a smooth finished surface. It has passed ISO 10993-5 cytotoxicity testing, according to the company.
Align is a polypropylene-like material designed for rigid corrective orthotics where structural support and consistent stiffness are required. Mosaic says Align has completed more than three million fatigue cycles.
Orion can produce patient-specific devices with variable-density structures, allowing their internal construction to be adjusted according to the required mechanical characteristics.
“Mosaic has spent more than a decade engineering additive manufacturing systems for real-world production, with a focus on automation, process control, and repeatable output,” said Derek Vogt, chief technology officer at Mosaic. “We’re applying that experience to orthotics with Orion, developing dedicated materials and a production system designed around the specific requirements of custom devices.”
Orion is available to order now. Mosaic is also offering sample devices and demonstrations of its Stryde Software Suite for orthotics manufacturers evaluating the platform’s device quality, workflow and production economics.
Scaling digital orthotics beyond print speed
Recent O&P deployments suggest that scaling 3D printed orthotics increasingly depends on the wider production workflow rather than print speed alone. Hike Medical operates more than 600 3D printers at its centralized Peoria facility, but argues that referral processing, insurance approval and device ordering can create delays that faster manufacturing cannot address by itself. Its response has been to connect these administrative and clinical stages with in-house production through a vertically integrated platform.
Production itself introduces further constraints as volumes increase. EOS highlighted throughput, labor, qualification documentation and post-processing among the factors affecting economically viable O&P manufacturing, noting that centralized production can remain preferable where the overhead of point-of-care printing outweighs shorter lead times. Orion approaches this production challenge at the lab level, using unattended sequential printing and a single platform for soft and rigid devices to reduce the amount of operator intervention required during production.
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Featured image shows the Orion 3D printing platform. Image via Mosaic.
