Orthogonality makes sense without character theory. There's an inner product on the space of representations given by $\dim \operatorname {Hom}(V, W)$. By Schur's lemma the irreps are an orthonormal basis. This is "character orthogonality" but without the characters.
How to recover the usual version from this conceptual version? Notice $\dim \operatorname{Hom}(V,W) = \dim \operatorname{Hom}(V \otimes W^*, 1)$$$\dim \operatorname{Hom}(V,W) = \dim \operatorname{Hom}(V \otimes W^*, 1)$$ where $1$ is the trivial representation. So in order to make the theory more concrete you want to know how to pick off the trivial part of a representation. This is just given by the image of the projection $\frac1{|G|} \sum_{g\in G} g$.
The dimension of a space is the same as the trace of the projection onto that space, so
$$
\def\H{\rule{0pt}{1.5ex}H}
\dim \operatorname{Hom}(V \otimes W^*, 1) = \operatorname{tr}\left(\frac1{|G|} \sum_{g\in G} {\large \rho}_{\small V \otimes W^*}(g)\right)
= \frac1{|G|} \sum_{g\in G} {\large\chi}_{V}(g)\ {\large\chi}_{W}\left(g^{-1}\right)
\\
$$ using the properties of trace under tensor product and duals.