A new automated 3D printing system, Orion, delivers an accessible, proven path to digital production for O&P labs and clinics, reducing manual steps and cost per pair while integrating seamlessly with existing workflows.
Toronto, Canada — [September 10, 2026] — Today, Mosaic Manufacturing Ltd. launched Orion, a purpose-built 3D printing platform designed to simplify, automate, and lower the cost of custom orthotics manufacturing. Built specifically for labs and clinics, Orion is a ready-to-deploy system that seamlessly bridges the gap between a digital design and a finished device. With an open-architecture workflow, it empowers businesses to automate the manufacturing of both soft and rigid patient-specific devices on a single platform, instantly upgrading production economics without disrupting existing clinical tools.
Digital orthotics production has long been a compelling path for the industry, but historically, the transition has been expensive, fragmented, and difficult to implement. Mosaic developed Orion by listening to the manufacturers and clinicians doing the work today – building an accessible, dedicated production system that is ready to deploy right now.
“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. They wanted an end-to-end, validated solution they could implement confidently and thrive with — and our team delivered. Orion makes digital orthotics production accessible today.”
Mitch Debora
CEO & Co-Founder at Mosaic Manufacturing
A Purpose-Built Production System
with Compelling Economics
Orion was designed from the ground up to solve the core challenge facing custom orthotics production today: how to manufacture patient-specific devices consistently, efficiently, and profitably without proportionally increasing manual labour or operational complexity.
At the core of the system is Orion’s belt-based 3D printing architecture, which eliminates the need for traditional production batching. One unique patient case can immediately follow another, while automated queue management enables continuous, unattended overnight and weekend production. Customers can adopt the complete Mosaic Stryde Software Suite to move from digital scanning through design and production management, replacing manual foam-box impressions and standalone design tools. Those with an established digital workflow can instead connect Orion to their compatible CAD/CAM setup, allowing them to keep the tools that already work for their business.
This combination of automation, reliability, and repeatability unlocks compelling value. Orion enables orthotics producers to:
Many of these projects involve:
- Scale effortlessly: Produce up to approximately 300 pairs per month, per Orion printer.
- Lower costs: Achieve material costs as low as approximately US$6 per pair, with a print time of roughly 1 hour and 45 minutes for a standard reference device.
- Empower technicians: Reduce material waste and downstream hand-finishing, freeing highly skilled staff to focus on complex clinical cases rather than repetitive manual work.
- Improve consistency: Use controlled digital production to deliver individualized devices with repeatable, high-quality output every time.
Dedicated Materials for Soft and Rigid
Devices
Orion manufactures custom orthotics using two proprietary Mosaic 3D printing materials engineered and rigorously tested specifically for orthotics. Crucially, the platform allows labs to produce both soft, accommodative insoles and rigid, corrective orthotics from a single system, featuring variable-density structures to meet specific patient requirements.
- Aero: An EVA-like 3D printing material for soft shell, accommodative orthotics. Engineered for comfort and resilience with a smooth, uniform finished surface, Aero has passed ISO 10993-5 biocompatibility testing for cytotoxicity.
- Align: A polypropylene-like material for rigid, corrective orthotics. It is engineered for high-support applications requiring structural control and consistent stiffness across every build, and has also successfully completed over three million fatigue cycles.
Supporting both accommodative and corrective orthotic devices on one 3D printing platform means O&P labs no longer need separate manufacturing workflows, separate equipment, or separate technicians for soft versus rigid custom orthotics.
“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. We’re applying that experience to orthotics with Orion, developing dedicated materials and a production system designed around the specific requirements of custom devices.”
Derek Vogt
Chief Technology Officer at Mosaic Manufacturing
Orion is now available, with Mosaic accepting orders for its purpose-built automated manufacturing platform for custom orthotics. Orthotics manufacturers can request sample devices and live demonstrations of the Stryde Software Suite to evaluate device quality, production workflow, automation, and cost-per-pair economics. Contact Mosaic directly to schedule a demonstration or discuss bringing Orion into your production environment.
For more information on Orion and Mosaic’s custom orthotics manufacturing platform, visit https://mosaicmfg.com/products-hardware/orion/
About Mosaic
Headquartered in Toronto, Canada, Mosaic Manufacturing helps organizations solve their most challenging production problems with end-to-end additive manufacturing solutions.
By combining advanced hardware, intelligent software, production-ready materials, and deep application expertise, Mosaic enables manufacturers to reduce labour, improve flexibility, and unlock new production capabilities that give their business a competitive advantage.
See Orion in Action
Orion is Mosaic’s purpose-built belt-based 3D printer for automated orthotics production, paired with the Stryde Software Suite for end-to-end digital workflow from scan to finished device.
Learn more or request sample devices.