American Orthodontics

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American Orthodontics‘ new 130,000-square-foot facility in Saukville represents a major expansion for the Sheboygan-based company, offering a state-of-the-art manufacturing and office space tailored for innovation, collaboration and employee well-being. Situated within the emerging Northern Gateway Community Collective, the facility is strategically positioned for efficient logistics, with close access to the interstate and a thoughtfully designed site plan that promotes smooth traffic flow and pedestrian connectivity.

Designed by Rinka and supported by engineering teams from Excel, Stantec and raSmith, the project exemplifies next-generation industrial architecture. Office and manufacturing spaces are seamlessly integrated to foster transparency and teamwork, while amenities such as a work café, lounges and outdoor patios encourage employee wellness and satisfaction. The building also features expansive daylighting, flexible layouts for future expansion and a welcoming aesthetic that reflects American Orthodontics’ forward-thinking brand.

The project faced several challenges, including the complexity of coordinating design and construction on a fast-tracked schedule and building on a wetlands site. Catalyst Construction leveraged Procore construction management software to streamline documentation, scheduling and communication across the entire project team. Weekly meetings and detailed tracking tools ensured transparency and adaptability throughout the build, while robust safety protocols — including third-party inspections and custom site orientations — kept workers safe.

Beyond operational excellence, the facility serves as an anchor for the broader Northern Gateway development, which will include housing, elder and child care and other essential services. This expansion underscores American Orthodontics’ long-standing commitment to community engagement, from local initiatives like Nourish Farms and Hmong cultural support to national leadership in orthodontic education and cancer research fundraising.

The Saukville project stands not just as a testament to smart design and execution, but as a meaningful investment in people and place.