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# Mosaic

## Sitemaps
- [XML Sitemap](https://mosaicmfg.com/sitemap_index.xml): Includes all crawlable and indexable pages.

## Posts
- [Mosaic Manufacturing Wins Best in Digital Showcase at AOPA 2026](https://mosaicmfg.com/mosaic-manufacturing-wins-aopa-award/): Toronto, ON — October 2026 — Mosaic Manufacturing Ltd. is proud to announce that it has been awarded Best in Digital Showcase at AOPA 2026, recognizing the company’s continued innovation in digital orthotic manufacturing and its contribution to the future of the O&P industry.
- [Advanced Variable Density 3D Printing for Custom Orthotics](https://mosaicmfg.com/advanced-variable-density-3d-printing-for-custom-orthotics/): Variable-density 3D printing allows different levels of firmness to be created within a single-material orthotic by changing its internal structure. Those regions are defined digitally before the device is printed.
- [Choosing a 3D Printer for Orthotics: Reliability, Support, and Total Cost](https://mosaicmfg.com/choosing-a-3d-printer-for-orthotics/): The purchase price of a 3D printer is easy to compare. Understanding what it will cost to keep an orthotics operation running takes a closer look.
- [Are 3D Printed Custom Foot Orthotics Covered by Insurance?](https://mosaicmfg.com/are-custom-foot-orthotics-covered-by-insurance/): 3D printed custom foot orthotics may be eligible for insurance reimbursement, but coverage depends on the patient’s plan, the condition being treated, the device provided and the insurer’s requirements for prescribing, dispensing and documentation.
- [Design Guidelines for Belt 3D Printing Custom Orthotics](https://mosaicmfg.com/belt-3d-printing-guidelines-for-orthotics/): What you’ll find inside:
- [Mosaic Launches Orion: A Simpler, Purpose-Built 3D Printing Platform for Custom Orthotics Production](https://mosaicmfg.com/mosaic-launches-orion-for-custom-orthotics/): 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.
- [Why Multi-Site Orthotics Labs Struggle with Standardization](https://mosaicmfg.com/why-multi-site-orthotics-labs-struggle/): Scaling an orthotics lab sounds simple: add locations, technicians, equipment. In practice, every new site and technician introduces variability. Devices from one location differ from another; a senior technician's output differs from a junior's, even from the same prescription.
- [Platform vs. Point Solutions: Why Orion Is Built as an Ecosystem](https://mosaicmfg.com/why-orion-is-built-as-an-ecosystem/): A platform connects those functions so data flows between steps without manual intervention, governed by the system rather than individual coordination. Orion and Stryde are a platform: Stryde Scan captures geometry and prescription details in one step; Stryde Design uses that data directly, no export or conversion; Stryde Manage tracks every patient and revision in one place; Stryde Print connects directly to Orion's continuous, automated production, no manual slicing or queue management.
- [Proven Performance: Do Orion’s Materials Perform Like EVA and Polypropylene?](https://mosaicmfg.com/do-orions-materials-perform-like-eva/): For good reason. EVA foam and polypropylene are the clinical benchmarks orthotics labs have built their practices around. They are known quantities: predictable in feel, predictable in performance, and predictable in how patients respond to them. Any new production technology entering the orthotics market has to answer directly to that standard, not in marketing language, but in clinical and mechanical terms.
- [From Scan to Finished Device: The Orion + Stryde Workflow Explained](https://mosaicmfg.com/the-orion-stryde-workflow-explained/): Orion and the Stryde Software Suite are built as a single connected system, not a collection of compatible tools, but a platform where data flows from capture through production without manual intervention at any step. Prescription intent established at the point of care is the prescription intent the finished device is built to. Every time.
- [Digital Orthotics Workflows: What Clinicians Need to Know About Orion](https://mosaicmfg.com/digital-orthotics-workflows-orion/): Most clinicians prescribing custom orthotics, podiatrists, chiropodists, pedorthists, chiropractors, physiotherapists, are not manufacturers. They assess patients, prescribe devices, and rely on a lab relationship to deliver orthotics that meet the clinical specification they've defined. The production method used by the lab is, in most cases, secondary to two things: whether the device performs as prescribed, and how long it takes to arrive.
- [The Economics of Scaling Orthotics Production With Orion](https://mosaicmfg.com/the-economics-of-scaling-orthotics-production/): The economics of orthotics lab growth are well understood, and for most labs, they are the primary constraint on scale.
- [SLS vs. Orion’s Belt-Based 3D Printing for Orthotics: What’s the Difference?](https://mosaicmfg.com/sls-vs-orions-belt-based-for-orthotics/): When orthotics labs evaluate 3D printing for custom device production, two technologies dominate the conversation: powder-based systems, SLS (Selective Laser Sintering) and HP Multi Jet Fusion (MJF), and belt-based FFF systems like Orion by Mosaic Manufacturing.
- [The Hidden Cost of Manual Grinding and Finishing in Orthotics Labs](https://mosaicmfg.com/the-hidden-cost-of-manual-grinding-in-orthotics-labs/): Custom orthotics production still relies heavily on hands-on fabrication and finishing. For labs, central fabrication operations, and clinics considering in-house production, those manual steps can affect production capacity, consistency, turnaround, and how easily volume can grow.
- [3D Printing for Custom Orthotics: How Belt-Based Production Works](https://mosaicmfg.com/3d-printing-for-custom-orthotics/): Custom orthotics production often involves a combination of physical impressions, manual fabrication, fixed-batch manufacturing, and handoffs between clinics and production teams. These methods can produce effective patient-specific devices, but they can also make consistency, turnaround, and production planning more difficult as an organization grows.
- [Custom Foam Packaging for Medical Devices: Speed, Consistency & Compliance](https://mosaicmfg.com/custom-foam-packaging-for-medical-devices/): Medical device packaging isn't a commodity problem. The foam insert that protects a surgical instrument in transit, cradles a diagnostic device, or presents a capital equipment accessory for field service has to fit precisely, perform consistently, and be documented well enough to survive an audit. And in medical device development, designs change often — so the packaging has to keep up.
- [Mosaic Manufacturing and kristoFOAM Expand Advanced Manufacturing Capabilities with Automated 3D Printed Foam Technology](https://mosaicmfg.com/mosaic-kristofoam-automated-3d-printed-foam/): Automated 3D Printed Foam
- [No MOQs, No Lead Times: The Case for Onsite Foam Production](https://mosaicmfg.com/no-moqs-no-lead-times/): MOQs and Floor Inventory
- [3D Printed Inserts: From Packaging to Shadow Boards and WIP Trays](https://mosaicmfg.com/3d-printed-inserts-shadow-boards-wip-trays/): In manufacturing environments, foam inserts support everyday operational workflows: shadow boards keep tools organized, WIP trays protect parts between operations, dunnage reduces transit damage, and packaging inserts protect finished products.
- [3D Printed Foam Packaging Solutions: A Buyer’s Guide for Industrial Teams](https://mosaicmfg.com/a-buyers-foam-guide-for-industrial-teams/): 3D printing is a tool. A good one, for the right applications. For industrial packaging and foam insert production specifically, it solves a narrow but important set of problems that traditional manufacturing handles poorly: low-volume custom work, fast iteration, multi-site consistency, and on-demand production without supplier dependency.
- [Custom Foam Packaging Inserts: When to Replace Die-Cut Foam with 3D Printing](https://mosaicmfg.com/when-to-replace-die-cut-foam-with-3d-printing/): Every foam fabricator knows the math. A customer calls with a twenty-unit order for a custom case insert with an irregular profile, maybe a camera body, a precision tool, something with pockets and contours. The job will take half a day to cut, laminate, and finish. The set up time alone eats the margin. You quote it anyway because the account matters, and you absorb the loss.
- [The Complete Guide to 3D Printed Foam: Custom Packaging, Organization & Production Solutions](https://mosaicmfg.com/complete-guide-to-3d-printed-foam/): Foam is everywhere in manufacturing: protecting parts in transit, organizing tools on factory floors, cushioning sensitive equipment, and supporting production workflows.
- [Advancing Protective Case Manufacturing: Cases Unlimited x Mosaic Case Study](https://mosaicmfg.com/advancing-protective-case-manufacturing/): Advancing Protective Case
- [Advancing Pharmaceutical Packaging: SWE x Mosaic Case Study](https://mosaicmfg.com/advancing-pharmaceutical-packaging-mosaic-case-study/): Advancing Pharmaceutical Packaging with Industrial 3D Printing & Engineered Foam Manufacturing
- [Additive Manufacturing in Aerospace & Defence: Applications, Materials & Industry Growth](https://mosaicmfg.com/additive-manufacturing-in-aerospace-defence/): Additive manufacturing in aerospace and defence has moved well past the prototyping stage. Across the global defence industrial base, 3D printing for aerospace and military applications is now being evaluated and deployed as a core production capability. It is reshaping supply chains, enabling on-demand production, and giving defence organizations a level of manufacturing agility that traditional methods simply cannot match.
- [Scaling Custom Orthotics: How Large Orthotics Labs Increase Throughput Without Increasing Headcount](https://mosaicmfg.com/scaling-custom-orthotics/): At volumes of 10,000 to 100,000+ pairs per year, the challenge is no longer demand. It is producing custom orthotics consistently across teams, shifts, and facilities without performance drift.
- [New: On-Device AI Print Failure Detection for Production-Scale Additive Manufacturing](https://mosaicmfg.com/ai-print-failure-detection/): This article explains how Mosaic’s AI Print Failure Detection uses on-device computer vision to identify failures as they happen, how it integrates with Element and Array, and why local AI processing improves throughput, security, and production reliability.
- [3D Scanning for Foot Orthotics: Turning Digital Foot Scans Into Reliable Repeatable Production](https://mosaicmfg.com/3d-scanning-for-foot-orthotics/): For small and mid-sized orthotics labs, 3D scanning for foot orthotics often starts as a clinical upgrade. Faster intake. Cleaner records. Digital archiving.
- [Using Array for Orthotics: High-Throughput 3D Printing for Custom Orthotics](https://mosaicmfg.com/using-array-for-orthotics/): Mosaic Manufacturing’s Array platform brings automation and reliable throughput to orthotics production; helping labs achieve precise, repeatable outcomes while reducing manual effort. Ensuring consistently high performance from Array involves straightforward maintenance detailed in this document.
- [3D Printing at Scale – How To Overcome Workflow Challenges with Automation](https://mosaicmfg.com/3d-printing-at-scale/): This in-depth guide explores how automation in additive manufacturing transforms 3D printing from a prototyping tool into a scalable, production-ready manufacturing solution
- [Smarter by Design: Reducing Part Costs With DfAM](https://mosaicmfg.com/smarter-by-design-reducing-part-costs-with-dfam/): Whether your goal is to reduce per-part costs, accelerate production, or scale economically, these DfAM strategies will help you get there.
- [How FDM 3D Printing Enables Repeatable, Scalable Orthotics Manufacturing](https://mosaicmfg.com/how-fdm-3d-printing-enables-orthotics-manufacturing/): For orthotics laboratories, the shift to 3D printed orthotics is not about adopting a new technology, it is about gaining tighter control over manufacturing variables that directly affect clinical outcomes.
- [Aero & EVA-Style Orthotics: How 3D Printing Is Transforming Custom Orthotics](https://mosaicmfg.com/aero-eva-style-orthotics/): EVA-style orthotics and custom orthotics play a crucial role in treating complex or sensitive foot conditions; from diabetic ulcer management and plantar fibromas to Charcot deformities and severe pressure points.While traditional EVA and alloplast devices remain effective, new digital manufacturing methods are changing what clinics and labs can offer, especially when it comes to precision, consistency, and multi-density performance.
- [Form & Functional Orthotics: How 3D Printing Is Redefining Bio-mechanical Correction](https://mosaicmfg.com/form-functional-orthotics/): Functional orthotics have long relied on rigid polypropylene (PP) shells for corrective support, durability, and low-profile performance. While polypropylene remains the industry standard for many prescriptions, modern 3D printing processes enhance the production of traditional PP-style shells through advanced material formulations. These improvements deliver greater consistency, durability, and repeatability, while significantly improving lab efficiency and ease of production.
- [Choosing a 3D Orthotics Manufacturing Partner That Delivers Results: How Digital Orthotics Ensure Clinical Consistency](https://mosaicmfg.com/choosing-a-3d-orthotics-manufacturing-that-delivers/): For clinics, consistency is an operational requirement, not a nice-to-have. When patients return for follow-ups, adjustments, or repeat pairs of custom orthotics, they expect the same fit, function, and comfort every time. Yet many variations in orthotic insoles are not caused by diagnosis or prescription, but by how devices are manufactured inside the orthotics laboratory. Yet many variations in orthotic insoles are not caused by diagnosis or prescription, but by how devices are manufactured inside the orthotics laboratory. Modern manufacturing platforms like Orion were designed specifically to address this challenge by embedding consistency directly into the production process, reducing variability introduced by manual fabrication and technician-dependent workflows.
- [Faster Turnaround, Happier Patients: Proven Ways How Clinics Can Reduce Orthotics Wait Times](https://mosaicmfg.com/how-clinics-can-reduce-orthotics-wait-times/): For clinician-led practices, including podiatrists, chiropodists, and foot care practitioners, turnaround time is no longer a secondary consideration. Patients increasingly expect custom orthotics to arrive quickly, fit correctly the first time, and require minimal follow-up. When delivery stretches into weeks, satisfaction drops, trust erodes, and clinics absorb hidden operational costs.
- [Multi-Material Printing with Palette Plus](https://mosaicmfg.com/multi-material-printing-with-palette-plus/): In contrast, a polymer alternative made from PEEK can weigh less than 700 grams—reducing weight by over 65%—while maintaining comparable strength and thermal resistance. A single spool of PEEK filament costing approximately $600 can produce dozens of such parts, drastically lowering material costs and eliminating many supply chain risks.
- [Traditional vs. 3D Printed Orthotics: The Complete Guide to Custom 3D Printed Insoles](https://mosaicmfg.com/traditional-vs-3d-printed-orthotics/): 3D-printed orthotics significantly enhance patient outcomes by delivering a faster, more streamlined, and digitally driven experience. The use of digital scanning and design enables rapid turnaround times, reducing the long waiting periods traditionally associated with orthotic fabrication. This modern, technology-based approach aligns with patient expectations for convenience and personalization, creating a smoother and more satisfying treatment journey.
- [Accelerating Local Electronics Manufacturing with Additive Automation: Mosaic and MicroArt](https://mosaicmfg.com/accelerating-local-electronics-manufacturing-with-additive-automation-mosaic-and-microart/): Located in Markham, Ontario, MicroArt Services Inc. is a leading electronics manufacturing and design company supporting clients through every stage of product development, from PCB layout and assembly to prototyping and box-builds. With deep expertise across industries such as medical, industrial automation, energy, and consumer electronics, MicroArt specializes in mid-volume production and quick-turn manufacturing, helping customers bring complex electronic products to market efficiently and reliably.
- [Design for Additive Manufacturing: How to Cut 3D Printing Costs Without Compromising Performance](https://mosaicmfg.com/design-for-additive-manufacturing-how-to-cut-3d-printing-costs-without-compromising-performance/): Unlock three powerful DfAM strategies to optimize part design, streamline production, and reduce total cost in additive manufacturing.
- [Scaling the Production of Custom Orthotics with Additive Manufacturing: Mosaic and Premier Orthotics Lab](https://mosaicmfg.com/scaling-the-production-of-custom-orthotics-with-additive-manufacturing-mosaic-and-premier-orthotics-lab/): Located in Ontario, Canada, Premier Orthotics Lab (POL) produces custom orthotics and footwear for a variety of different clients including chiropractors, podiatrists, doctors, and foot care practitioners. With over 15 years of expertise, POL has cemented itself as an industry leader, earning a reputation for delivering high quality custom orthotics while offering exceptional customer service.
- [Array System vs. Formlabs Series 3 + FormAuto Attachment](https://mosaicmfg.com/comparison-formlabsseries3/): Introduction
- [Array System vs. Stratasys F370: What Manufacturers Need to Know](https://mosaicmfg.com/comparison-f370/): Stratasys F370
- [Automated 3D Printing for Service Bureaus: Inside Avid’s Shift to Array for Scalable Manufacturing](https://mosaicmfg.com/automated-3d-printing-for-service-bureaus-inside-avids-shift-to-array-for-scalable-manufacturing/): Located in Loveland, Colorado, Avid Product Development -- a Lubrizol company -- is a seasoned 3D printing service bureau with over a decade of experience. Specializing in parts for automotive, healthcare, jigs, and fixtures, Avid operates at the intersection of precision and production, delivering thousands to tens of thousands of components each week. But as customer demands shifted toward serial production, their traditional workflow began to show its limits.
- [How to Deploy Additive Manufacturing into Your Supply Chain](https://mosaicmfg.com/supply-chain-white-paper/): Facing unstable supply chains and challenging market conditions, manufacturers are turning to additive manufacturing to future-proof their operations.
- [Sparking Innovation Through Collaborative Manufacturing Events](https://mosaicmfg.com/sparking-innovation-through-collaborative-manufacturing-events/): At Mosaic Manufacturing, we’re not just passionate about creating cutting-edge 3D printing technology – we’re dedicated to building a thriving ecosystem of innovation. That’s why we’ve been thrilled to open the doors of our headquarters and collaborate with leading voices in tech. Together, we’re hosting a series of vibrant, idea-driven hardware meetups that are reshaping how innovation happens in North America.
- [Replacing Steel and Aluminum with 3D Printed Polymer Parts](https://mosaicmfg.com/replacing-steel-and-aluminum-with-3d-printed-polymer-parts/): Geopolitics Garner International Trade Tensions
- [The Future of Orthotics Production](https://mosaicmfg.com/the-future-of-orthotics-production/): Up until now, the process of creating custom orthotics has been a laborious and time consuming practice. Practitioners work from casts and molds created from each patient to produce unique parts which must then be milled, ground, and precisely adhered together in layers. The amount of time and specialization required has limited both the quality and output of orthotics, resulting in increased costs for practitioners and longer wait times for patients. In order to combat these inefficiencies, companies have turned to additive manufacturing to enable the production of custom orthotics at scale.
- [Understanding Heated Beds and Chambers](https://mosaicmfg.com/understanding-heated-beds-and-chambers/): When it comes to Fused Filament Fabrication (FFF) 3D printing, one of the most important factors that can greatly impact the quality of your prints is temperature control. In particular, using a heated bed and/or a heated chamber can make a significant difference in the outcome of your prints. In this blog post, we’ll explore why using a heated bed and/or chamber is so important in FFF 3D printing.
- [ABS vs ASA](https://mosaicmfg.com/abs-vs-asa/): ABS (Acrylonitrile Butadiene Styrene) and ASA (Acrylonitrile Styrene Acrylate) are two popular thermoplastics used in 3D printing.

## Pages
- [Stryde Print](https://mosaicmfg.com/product-software/stryde-print/): 00000
- [Stryde Scan | Digital Foot Scanning for O&P](https://mosaicmfg.com/product-software/stryde-scan/): 00000
- [Stryde Design](https://mosaicmfg.com/product-software/stryde-design/): 00000
- [Stryde Software Suite](https://mosaicmfg.com/product-software/stryde-software-suite/)
- [Part Production | Core Application Page 2026](https://mosaicmfg.com/part-production/)
- [3D Printed Foam](https://mosaicmfg.com/3d-printed-foam/)
- [Orion | Automated 3D Printer for Custom Foot Orthotics](https://mosaicmfg.com/orion/)
- [Jigs & Fixtures](https://mosaicmfg.com/jigs-fixtures/)
- [Spare Parts](https://mosaicmfg.com/use-cases-applications-spare-parts/)
- [Contract Manufacturing](https://mosaicmfg.com/contract-manufacturing/)
- [Materials Detail – Stitch](https://mosaicmfg.com/materials-detail-stitch/)
- [Orthotics](https://mosaicmfg.com/use-cases-applications-orthotics/)
- [Return & Refund Policy](https://mosaicmfg.com/return-refund-policy/): Note: This policy applies to purchases made directly from Mosaic (e.g., via our official website/store or direct sales team). If you purchased through a third-party reseller or distributor, their return policies may apply, but they often coordinate with Mosaic’s guidelines. We advise you to register your product with Mosaic and work with the original seller for returns, as needed.
- [Materials Detail – PEKK](https://mosaicmfg.com/materials-detail-pekk/)
- [Materials Detail – PEEK](https://mosaicmfg.com/materials-detail-peek/)
- [Materials Detail – ESD-PETG](https://mosaicmfg.com/materials-detail-esd-petg/)
- [Materials Detail – FR-PC](https://mosaicmfg.com/materials-detail-fr-pc/)
- [Materials Detail – Nylon](https://mosaicmfg.com/materials-detail-nylon/)
- [Materials Detail – Aero](https://mosaicmfg.com/materials-detail-aero/)
- [Materials Detail – Mosaic Matrix](https://mosaicmfg.com/materials-detail-mosaic-matrix/)
- [Materials Detail – Mosaic Flex](https://mosaicmfg.com/materials-detail-mosaic-flex/)
- [Materials Detail – PLA](https://mosaicmfg.com/materials-detail-pla/)
- [Materials Detail – ASA](https://mosaicmfg.com/materials-detail-asa/)
- [Materials Detail – ABS](https://mosaicmfg.com/materials-detail-abs/)
- [Mosaic Part Production – Terms & Conditions](https://mosaicmfg.com/part-production-terms-conditions/): The Customer agrees to indemnify, defend, and hold harmless the Service Provider from any and all claims, damages, or legal fees arising from:
- [Orthotics Production Automation](https://mosaicmfg.com/solutions/orthotics-production-automation/)
- [Company](https://mosaicmfg.com/company/)
- [Warehousing & Logistics](https://mosaicmfg.com/warehousing-logistics/)
- [Robotics](https://mosaicmfg.com/robotics/)
- [About](https://mosaicmfg.com/about-2/)
- [Sustainable Manufacturing](https://mosaicmfg.com/solutions/sustainable-manufacturing-2/)
- [Digital Inventory Management](https://mosaicmfg.com/solutions/digital-inventory-management-2/)
- [Customization at Scale](https://mosaicmfg.com/solutions/customization-at-scale-2/)
- [Mosaic Solutions](https://mosaicmfg.com/deployment/mosaic-solutions-3/)
- [Canvas](https://mosaicmfg.com/product-software/canvas-3/)
- [Canvas](https://mosaicmfg.com/product-software/canvas-2/)
- [Tooling](https://mosaicmfg.com/use-cases/applications/tooling-2/)
- [Education](https://mosaicmfg.com/use-cases/industries/education-3/)
- [Made in Canada](https://mosaicmfg.com/made-in-canada/)
- [Array | Version B](https://mosaicmfg.com/products-hardware/array-2/)
- [Patents](https://mosaicmfg.com/patents/)
- [Terms & Conditions](https://mosaicmfg.com/terms-conditions/): Scope and Application: These Terms and Conditions of Sale (“Terms”) govern all sales of Mosaic Manufacturing Ltd. (“Mosaic”) products and services, including hardware (such as Array™, Element™ devices), software (such as Canvas™ platform licenses or subscriptions), service plans, accessories, and materials, whether sold directly by Mosaic or through an authorized reseller or distributor. By placing an order or accepting delivery of Mosaic products or services, the purchaser (“Customer”) agrees to these Terms, which shall apply in addition to any specific terms in Mosaic’s quotes, invoices, purchase orders, or order confirmations. In the event of any conflict, these Terms prevail unless a separate written agreement is signed by Mosaic’s authorized representative. These Terms are suitable for inclusion with all order documentation (quotes, POs, invoices, order confirmations) to ensure a consistent understanding between Mosaic and the Customer.
- [Warranty & Return Policy](https://mosaicmfg.com/warranty/): Effective Date: December 1, 2025
- [Mosaic Solutions](https://mosaicmfg.com/deployment/mosaic-solutions/)
- [Deployment](https://mosaicmfg.com/deployment/)

## Testimonial