US Patent 11523881 Prediction of aligner progressive damage using simulation

Embodiments relate to an aligner breakage solution that tests progressive damage to an aligner. A method includes gathering a digital model representing an aligner for a dental arch of a patient, and simulating progressive damage to the aligner. Simulating progressive damage for a region of the aligner comprises simulating, using at least the digital model, a sequence of loads on the aligner, determining an amount of damage to the region of the aligner for each load, and after each simulation of a load on the aligner, updating the digital model based on the amount of damage to the region of the aligner. The method further includes determining whether a damage criterion is satisfied for at least one region of the aligner and determining whether to implement one or more corrective actions for the aligner.