Order-to-cash ERP for a US orthotic and prosthetic manufacturing lab
Every device this lab makes is built to one patient's anatomy, starting from a 3D foot scan rather than a stock SKU. We built the order-to-cash ERP end to end: browser-based scan measurement, production scheduling across two stages, a self-service doctor portal, and two separate AI integrations turning scanned paperwork and free-text data into structured records.
- CLIENT
- A US orthotic and prosthetic manufacturing lab
- INDUSTRY
- Custom medical device manufacturing
- ENGAGEMENT
- ERP architecture, development and long-term support, ongoing
- STACK
- ASP.NET Web Forms, ASP.NET Core, SQL Server, Three.js, QuickBooks API, CardKnox, Stamps.com / USPS API
Every unit is made to one patient, and the spec arrives as a 3D scan, not a SKU.
- No way to capture and measure a patient-specific 3D foot scan without specialized CAD software
- No single system covering order intake, production scheduling, inventory, shipping and accounting together
- No self-service order submission or status visibility for a large, distributed network of doctor practices
- No production-floor tools usable by lab staff without training on a general-purpose ERP screen
- No reliable, automatic reconciliation between a high volume of orders and QuickBooks
- Referring offices still submit paper work orders by hand, fax or email rather than digitally
One system, built around how the work actually happens.
Browser-based measurement viewer
A Three.js application inside the existing ERP displays left and right foot scans side by side, with preset and custom named measurement lines placed by clicking two points on the mesh. Measurements save in the background without reloading the page, adding a modern client-side tool to an existing application without a platform rewrite.
A digital work order that mirrors the paper form
Every clinical field is driven by an admin-configurable option table rather than hardcoded, so the form can change without a code change. A two-way messaging thread between doctor and lab is attached to each order and triggers email on status change.
Two independently scheduled stages
Glue and lab production run as separate scheduling grids with their own shop-floor screens, plus landed-cost purchasing that rolls duty, tariff and freight into a computed cost per unit at the time of receiving.
Self-service for doctor practices
A permission-gated portal lets each practice submit orders through the same screen the lab uses internally, track status, view invoices, and see a patient-level re-order reminder list, with OTP authentication across multiple practices per login.
Two separate AI integrations in production
Scanned paper work orders are extracted directly into structured digital orders through an AI document pipeline, and a separate integration resolves inconsistently written practice names on incoming orders to the correct physician record.
Payment and reconciliation built into AR
Staff charge saved cards on file directly from the invoice screen, with a successful charge syncing the invoice as paid in QuickBooks automatically, alongside commission tracking calculated per invoice by sales person and practice.
What it runs on.
What changed.
- A single system running the full order-to-cash cycle for a custom-manufacturing business, replacing paper work orders and disconnected tracking
- Browser-based 3D measurement replacing manual, paper-based anatomical capture
- Import and landed-cost calculation built directly into purchasing rather than handled outside the system
- A large network of doctor practices ordering, tracking and re-ordering through their own self-service portal
- Automated QuickBooks reconciliation with a full sync audit trail, at high order volume
- Two AI integrations in production: one turning scanned paperwork into structured orders, one resolving practice names to the correct physician record
This page shows no percentages or figures because none have been confirmed by the client for publication. Where a number is not verified, it is left out rather than estimated.
After go-live.
The system has grown from order tracking and a doctor portal into a full manufacturing ERP and remains under active development. The 3D measurement viewer, landed-cost purchasing and AI-assisted practice matching were all added without a platform rewrite.
The work behind this project.
Running into something similar?
Describe what you are dealing with and we will tell you honestly whether this is a pattern we have solved before.