Orchid Orthopedic Solutions is a worldwide leader in medical contract design and manufacturing solutions for the orthopedic, dental and cardiovascular markets. Orchid's key mission is to be the leader in contract medical design and manufacturing by compressing time to market, providing new technology and being the best total supply chain value. The company meets the ISO 13485:2003 international standard for medical devices and related services that consistently meet customer requirements and regulatory requirements. The company consists of nine divisions that offer an array of implants and instruments within the five core capabilities: design, forging, machining, plastics and coatings.

Forging Capabilities

• Innovative engineering including concept, design and prototyping solutions for efficient and cost effective production
• Net and near-net forging producing products that are higher in quality and lower in cost
• Complete machining capabilities for hard-die manufacturing and machining of implants
• Lean manufacturing including value stream mapping and Kaizen events to ensure processes are optimized and all wasted cost is removed

Machining Capabilities

• Includes Swiss-style and conventional turning, milling, grinding and EDM machines
• Special processes like color coding, laser welding, cutting and etching, diamond coating, gundrilling and micro deburring
• Vertical integration parts can be manufactured, laser marked, cleaned, passivated, packaged and sterilized in one location
• Engineering support including material selection, prototypes, performance enhancement and design for manufacturing
• Packaging and labeling both sterile and non-sterile

Design and Development Capabilities

• Comprehensive concept development an exploration of new, alternative design approaches
• Thorough feasibility confirmation achieved through careful analysis, prototyping and testing
• In-depth design services resulting in cost effective and robust designs
• Functional prototyping quickly created with our state-of-the-art fabrication equipment
• Qualification testing including bench top, animal and cadaver evaluations
• Small scale / pilot manufacturing for clinical trials, market evaluations, customs or validations
• Quality and regulatory consulting for medical device and healthcare product companies

Plastic Machining Capabilities

• CNC plastics machining ranging from five-axis milling to live-tool turning centers with sub-spindles
• Access to a wide range of medical grade plastics including implant grade UHMWPE, high temperature resistant engineering plastics, thermoplastic resins and biodegradable polymers
• Plastics injection molding multiple presses with 30-150 tons of clamping force for small, medium and high volume runs
• Portable Class 10,000 controlled environment rooms offering a high degree of protection from particulate contamination
• Product cleaning and assembly conducted within our permanent Class 10,000 controlled environment room
• Product packaging including pouch or blister sealing
• Boxing, labeling and shrink-wrapping that produce a product ready for sterilization

Coating Capabilities

• Proprietary Hydroxylapatite Coating (HA) on titanium, cobalt-chromium or stainless steel
• Titanium Plasma Spray (TPS) on Titanium or CoCr substrates with a purity that enables the coating to exceed the ASTM requirement eliminating cracking
• Resorbable Blast Media (RBM) surface treatment on Titanium substrates creating a roughened surface comparable to a 100 mesh Al₂0₃ finish without leaving any embedded debris
• Composite coatings including HA on plasma, beads, chemtex and irregular sintered coatings, as well as TPS on RBM-prepared substrates
• Porous coatings such as spherical bead, asymmetrical powder and irregular particle coatings, available in a range of powder sizes, types and coating processes to meet tight tolerances or unusual specifications
• Quality control including visual, dimensional and mechanical testing as well as NDT capability
• Final clean and sterile packaging

Packaging Capabilities

• Flexible and rigid packaging design
• Validated final cleaning process to ensure your devices are clean and ready for sterilization
• Detection of seal leaks, seal strength, distribution simulation and shelf-life testing
• Our ISO certified cleanrooms are regularly monitored for temperature, humidity, particle counts and bioburden (ISO11737)
• Packaging validations are planned to ensure that the requirements of ISO11607 can be met
• Orchid offers gamma radiation and ethylene oxide sterilization management and post-sterilization release activities
• Our labeling capabilities include barcoding and a vast symbol library, including MDD and ISO15223 Medical Devices

Major Markets
Orchid Orthopedic Solutions specializes in implants, instruments and innovative technologies for the following markets:

• Reconstruction
• Trauma
• Spine
• Sports medicine
• Orthobiologics
• Extremities
• Dental
• Medical devices

Services Offered
Orchid Orthopedic Solutions' divisions offer the following products and services:

• Contract design (implant and instrument systems, design trouble-shooting, customs and specials and gage design and fabrication)
• Near-net forging  (joint and bosddne replacement components, plates and extremity parts)
• Advanced machining (implants, surgical instruments, screws, nails, plates and joint replacement parts)
• Medical-grade precision-machined and molded plastic products (medical devices, implants, components and delivery systems)
• HA, TPS, RBM, porous and bead coatings and surface treatments (implants)
• Sterile packaging (flexible and rigid, packaging design, final cleaning, testing, monitoring, validation, sterilization and labeling)

Year Founded:2005
Number of Employees: 1,000+
Number of Facilities: 10