American Orthodontics

American Orthodontics is a family-owned manufacturer of orthodontic treatment products — including brackets, wires, bands, tubes, and ligatures used by orthodontic specialists. Founded in 1968 by Dan Merkel, the company is headquartered in Sheboygan, Wisconsin, and is recognized as one of the world's largest companies in its category.

The company employs more than 700 people worldwide and does business in over 110 countries. Roughly 98% of its products are manufactured in-house at its approximately 280,000-square-foot Sheboygan facility, keeping operations and office functions under one roof for tighter quality control. A reported expansion includes plans to invest about $25 million in a new facility in Saukville, Wisconsin, plus an additional $15 million into the existing Sheboygan operation (per secondary reporting).

Manufacturing relies on advanced techniques including powdered metal injection molding, sintering, automated and CNC Swiss screw machining, 3D printing, laser welding/marking, and diamond wet grinding — all managed to comply with medical-device regulations across global markets. The company positions itself as a long-standing product innovator, crediting its R&D with introducing the first latex-free elastics, and has been repeatedly recognized in the Orthotown Townie Choice Awards.

Given this emphasis on in-house advanced manufacturing and R&D-driven product innovation, developments in this space are directly relevant to American Orthodontics.