The Power of Partnership
Orchid has spent the last few years building a new platform for additive manufacturing using EBM technology —one designed specifically for the challenges of large joint orthopedic implants. We’ve invested in the technology, the processes, and the people needed to build next-generation devices.
Maxx Ortho and Orchid united with a shared vision: to move beyond the limitations of traditional orthopedic implants and bring cutting-edge, cementless solutions to market faster and more cost-effectively. What emerged is not just a novel FREEDOM® porous knee, but a blueprint for future innovation.
The Freedom Porous Knee project was a real example of co-development—starting with design feasibility and extending through additive builds, machining, surface treatments, finishing and validation. We worked through design challenges together and strategically aligned on resources and capabilities of both entities. We learned from one another.
“Our team was empowered to solve problems in real time, and Maxx Ortho matched that energy. They came to the table with an innovative design and a clear vision and partnered with us throughout the project. We used Orchid’s NPI (new product introduction) process as our backbone, but what really made this project move was the collaboration and mutual trust between teams. We met with Maxx Ortho regularly, worked through their questions for the 510(k), and stayed focused on what success would look like for them. Everyone cared about the outcome,” said Melissa Fowler, Orchid’s Director of Additive Manufacturing.
This collaboration combined Maxx Ortho’s deep product design expertise with Orchid’s legacy in orthopedic manufacturing and pioneering work in 3D printing. Together, we have redefined what’s possible in joint replacement technology.
“This project worked because Maxx Ortho and Orchid were ready to solve problems together and leverage our respective strengths. Orchid had the additive platform and manufacturing depth, and we had a clear vision of the product features and benefits we wanted to offer to the market. We collaborated from day one, moved fast, and delivered something that’s not just manufacturable but impactful to surgeons and patients,” said Corey Perine, Chief Operating Officer of Maxx Orthopedics.
Maxx Ortho’s Design, Enabled by Additive Manufacturing
At the center of this breakthrough is Maxx’s unique tibial baseplate design—engineered for both immediate press-fit stability and long-term biological fixation. The ability to include complex features, like a zero-angle keel with a prominent edge, resulting in minimum bone loss, was made possible only through additive manufacturing. Traditional manufacturing techniques could not support such intricate geometries without compromising material integrity. But with 3D printing, Maxx realized a design that minimized bone volume loss during resection while maximizing initial fixation and promoting long-term bone in-growth.
Traditional manufacturing techniques could not support such intricate geometries without compromising material integrity. But with 3D printing, Maxx realized a design that minimized bone volume loss during resection while maximizing initial fixation and promoting long-term bone in-growth.
Critically, the use of titanium Grade 23 (Eli)—a cleaner, tougher alloy than the industry-standard Grade 5—allowed Maxx to introduce thinner cross sections and advanced lattice structures without sacrificing performance. The improved ductility and toughness of Grade 23 were essential in realizing the design vision.
“Additive manufacturing plays a significant role in advancing the design and functionality of porous orthopedic implants. It has freed the development of cementless implants from decades of design limitations. Contrary to traditional methods, new structural possibilities are far more flexible, with virtually unlimited variations,” Perine said.
Lattice Innovation for Bone In-Growth
A defining feature of the new baseplate is its proprietary 3D-printed lattice structure. Developed by Orchid using its years of experience in applying coatings to various large joints, it mimics a bone in-growth structure with a long clinical history and adds features which weren’t possible with conventional bead sintering or Titanium Plasma Spray (TPS). The lattice structure offers:
- High Coefficient of Friction: Enhances scratch-fit during impaction, creating immediate mechanical interdigitation.
- Open, Interconnected Porosity: Encourages vascularization and deep bone in-growth, promoting long-term stability.
- Micro-Roughness: Aids osteoblast attachment for biological integration.
- Protruding Rails: Create intentional interference, improving initial fixation.
- Abrasion Resistance: Compliant with FDA guidelines, the structure resists wear and material shedding.
What sets this lattice apart is that it mimics successful bead-sintered coatings while leveraging the design flexibility of AM. Orchid’s experience in bone in-growth technologies informed the creation of this lattice, delivering a solution backed by clinical precedent and manufacturing excellence.
“Bringing this to life took more than just machines—it took people, expertise, and a shared commitment to innovation. Our technical team has extensive experience in porous surface characterization and developed our proprietary lattice structures,” Fowler said.
Time, Cost, and Confidence: The Orchid Advantage
Orchid brought more than machines to the table. With more than 60 years of orthopedic manufacturing experience, including expertise in casting, forging, finishing and bone in-growth coating. Our customers experienced bottlenecks post-printing finishing process and Regulatory support related to Additive Manufacturing process, resulting into significant creeps in the project timelines. o Orchid offered a full end-to-end solution—spanning design-for-AM (DFAM), regulatory navigation, finishing, and scalable production.
In addition to creating the possibility for Maxx to explore more complex tibia designs, Orchid’s vertically integrated AM platform, built and operated entirely in the U.S., enabled faster development cycles, reliable supply chain management, and reduced time-to-market compared to conventional methods. Orchid’s ability to conduct certain porous surface related tests in-house further helped in improving project timelines. Maxx was able to meet an accelerated launch date, faster than would be typical with conventional manufacturing.
Maxx was able to meet an accelerated launch date, faster than would be typical with conventional manufacturing.
Speed-to-market is only part of the equation. To serve a cost competitive orthopedic market, new implants need to be delivered reliably and cost-effectively. By eliminating the need of an additional TPS or bead sintering coating process, creating large build volumes with minimal post processing requirements and reducing dependence on expensive tooling, Orchid’s AM process significantly lowered production costs compared to conventional manufacturing—all while expanding design possibilities.
“We took a big risk, moving from another supplier to Orchid during the development process. With Orchid, we saw an innovative company and a team who understood how to support an OEM navigating the regulatory submission process. They are using additive manufacturing technology in a way and at a scale that we haven’t seen others optimizing yet. Our risk paid off in a big way,” Perine said.
Engineering for the Future
This isn’t just about one implant. Maxx and Orchid have demonstrated a new possibility for how orthopedic products may be conceived, manufactured, and delivered. The success of this tibial baseplate paves the way for more 3D-printed solutions, tailored to meet the evolving needs of both surgeons and patients.
This project is one example that will continue building industry confidence in AM technology—not as a prototype tool, but as a mature, production-ready platform for orthopedic innovation.
What’s Next
As the orthopedic world leans into cementless solutions, Maxx’s designs prioritize long-term outcomes and surgeon confidence. With Orchid’s full-scale additive capabilities and regulatory know-how, new concepts can be realized faster, with fewer tradeoffs.
This collaboration is an example of how innovation doesn’t happen in isolation and doesn’t have to wait for years to get launched to market. It takes shared vision, complementary expertise, and a willingness to push boundaries. And when that happens, our industry can improve options for surgeons and patients.
Welcome to the future of orthopedic design—where collaboration meets capability, and innovation takes shape in titanium.
For more information:
Learn more about Maxx Ortho
Learn more about Maxx Ortho's Freedom Porous Knee
Learn more about Orchid's 3D printing ecosystem