Can Aligners Crack or Break?

    Posted on July 21, 2025• 📖 2 min read

    Table of Contents

    Can-Aligners-Crack-or-Break NewSmile™ USA

    Written by Joanne M., Director of Telehealth Clinical Operations | Fact-Checked for Clinical Accuracy

    Quick Answer: 🧩 Yes, clear aligners can crack or break. When it happens, don’t panic—most issues can be handled quickly by switching trays or contacting your provider.

    “I thought a small crack meant my treatment was ruined. Turns out, it was an easy fix.”

    🧩 Why Aligners Crack or Break

    Clear aligners are designed to be durable—but they’re still medical-grade plastic. Daily habits can put stress on the material, especially during removal or wear.

    • ✔ Removing aligners too forcefully from the front
    • ✔ Biting down on hard foods while wearing trays
    • ✔ Nighttime grinding or clenching
    • ✔ Tossing aligners into a bag without a case

    Most cracks happen gradually, which is why regular inspection matters.

    💪 How to Protect Aligner Durability

    A few simple habits can dramatically reduce the risk of damage.

    • ✔ Remove aligners from the back molars first
    • ✔ Store them in a protective case when not in use
    • ✔ Use chewies instead of biting trays into place
    • ✔ Avoid hot water, which can weaken plastic
    💡 Pro Tip: Aligners are meant to last 1–2 weeks per set. Gentle handling helps them do exactly that.

    🛠️ What to Do If Your Aligner Cracks

    Not all damage requires the same response. What you do next depends on the severity.

    Hairline crack

    • ✔ Best to stop wearing your aligner or retainer since its integrity has been compromised 
    • ✔ Skip to your next step, and make up for lost time i.e. you crack your aligner #5, and have 8 days left of wear time. Move on to aligner #6 and wear for 14 days (as directed) + 8 days missed by aligner #5. Aligner #6 is worn for a total of 22 days. 
      ✔ If your retainer is your last step, wear your retainer for 22 hours a day for the first 6 months, then during evenings as directed.

    Fully broken or loose aligner

    • ✔ Switch to your next set if you’re near your change date
    • ✔ Otherwise, wear your previous aligner to maintain progress
    • ✔ Contact your provider for guidance or a replacement
    ⚠️ Important: Wearing a broken aligner too long can cause poor tracking or sore spots.

    ⏳ When Damage Can Delay Treatment

    Ignoring cracked aligners may lead to setbacks such as:

    • ✔ Teeth not tracking as planned
    • ✔ Longer treatment timelines
    • ✔ Uneven pressure and discomfort

    Keeping your previous aligners until treatment ends gives you a built-in backup if damage occurs.

    💭 Final Thoughts

    Aligner damage is frustrating—but it’s rarely a deal-breaker. With quick action, good habits, and proper support, your treatment can stay right on track.

    Handle aligners gently, check them daily, and remember: most cracks are fixable without losing progress. 😌

    📚 References

    Table of Contents

    Written by Joanne M., Director of Telehealth Clinical Operations | Fact-Checked for Clinical Accuracy

    Quick Answer: 🧩 Yes, clear aligners can crack or break. When it happens, don’t panic—most issues can be handled quickly by switching trays or contacting your provider.

    “I thought a small crack meant my treatment was ruined. Turns out, it was an easy fix.”

    🧩 Why Aligners Crack or Break

    Clear aligners are designed to be durable—but they’re still medical-grade plastic. Daily habits can put stress on the material, especially during removal or wear.

    • ✔ Removing aligners too forcefully from the front
    • ✔ Biting down on hard foods while wearing trays
    • ✔ Nighttime grinding or clenching
    • ✔ Tossing aligners into a bag without a case

    Most cracks happen gradually, which is why regular inspection matters.

    💪 How to Protect Aligner Durability

    A few simple habits can dramatically reduce the risk of damage.

    • ✔ Remove aligners from the back molars first
    • ✔ Store them in a protective case when not in use
    • ✔ Use chewies instead of biting trays into place
    • ✔ Avoid hot water, which can weaken plastic
    💡 Pro Tip: Aligners are meant to last 1–2 weeks per set. Gentle handling helps them do exactly that.

    🛠️ What to Do If Your Aligner Cracks

    Not all damage requires the same response. What you do next depends on the severity.

    Hairline crack

    • ✔ Best to stop wearing your aligner or retainer since its integrity has been compromised 
    • ✔ Skip to your next step, and make up for lost time i.e. you crack your aligner #5, and have 8 days left of wear time. Move on to aligner #6 and wear for 14 days (as directed) + 8 days missed by aligner #5. Aligner #6 is worn for a total of 22 days. 
      ✔ If your retainer is your last step, wear your retainer for 22 hours a day for the first 6 months, then during evenings as directed.

    Fully broken or loose aligner

    • ✔ Switch to your next set if you’re near your change date
    • ✔ Otherwise, wear your previous aligner to maintain progress
    • ✔ Contact your provider for guidance or a replacement
    ⚠️ Important: Wearing a broken aligner too long can cause poor tracking or sore spots.

    ⏳ When Damage Can Delay Treatment

    Ignoring cracked aligners may lead to setbacks such as:

    • ✔ Teeth not tracking as planned
    • ✔ Longer treatment timelines
    • ✔ Uneven pressure and discomfort

    Keeping your previous aligners until treatment ends gives you a built-in backup if damage occurs.

    💭 Final Thoughts

    Aligner damage is frustrating—but it’s rarely a deal-breaker. With quick action, good habits, and proper support, your treatment can stay right on track.

    Handle aligners gently, check them daily, and remember: most cracks are fixable without losing progress. 😌

    📚 References

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