Mosaic Orion Is a 3D Printer Built Specifically for Custom Orthotics

A Purpose-Built Machine for a Fragmented Market

Mosaic Manufacturing has launched a 3D printing platform designed exclusively for custom orthotics production. Called Orion, the system targets orthotics and prosthetics labs that still use manual foam-box impressions and piecemeal digital tools. The company says Orion can produce roughly 300 pairs per month, at a per-pair cost around six dollars, with a print time of about one hour and 45 minutes.

The machine uses a belt-based architecture, which Mosaic says eliminates the need for traditional production batching. One patient case can immediately follow the next, and automatic queue management allows overnight and weekend runs without operator supervision. That is a meaningful shift for smaller labs that cannot staff multiple shifts.

Two Proprietary Materials for Both Device Types

Orion runs two Mosaic-developed materials. Aero is an EVA-like soft-shell material engineered for comfort and pressure distribution. It has passed ISO 10993-5 biocompatibility testing for cytotoxicity. Align is a polypropylene-like rigid material for corrective devices that need structural stiffness. Mosaic says Align has survived over three million fatigue cycles in testing.

By covering both soft and rigid devices on a single platform, Orion removes the need for separate manufacturing lines, separate equipment, and separate technicians for each device type. For labs that have been juggling multiple workflows, that consolidation is the main selling point.

Software as Part of the Package

Orion ships with the Mosaic Stryde Software Suite, which handles digital scanning, design, and production management. Labs that already use a compatible CAD/CAM system can connect Orion directly to that workflow instead. The goal is to replace the current stack of disconnected tools with something that walks a patient from scan to finished orthotic inside a single environment.

Mosaic has been building belt-driven 3D printing systems for more than a decade, mostly for industrial customers. Orion is its first machine built for a specific clinical workflow. The company says it spent considerable time with orthotics manufacturers before finalizing the design, which is why the output targets the cost and throughput constraints that smaller labs actually face.

Orion is now available through Mosaic's reseller network. Pricing was not disclosed in the initial announcement, but the company positioned the system as a way to bring digital orthotics production in-house without the capital outlay traditionally associated with industrial additive manufacturing equipment.