Re: How to found a new Catholic Order
Mother Teresa singlehandedly founded a new order of nuns. Not the same, but might be a good place to start research.
AT A GUESS, (1) Identify a need/mission that no current order fills, (2) convince a bishop or higher to sponsor the new order (3) work up the bureaucracy.
I thought a new order had been established recently ("recently" in terms of the Church, within the past 50 years or so) for the Anglican/Episcopalian priest who had converted to Catholicism, but a 3 minute google search could not confirm.