Embodiments relate to an aligner breakage solution that tests damage to an aligner using machine learning. A method includes processing data from a digital design for an orthodontic aligner by a trained machine learning model and outputting, by the trained machine learning model, a probability that the orthodontic aligner associated with the digital design will be damaged during manufacturing of the orthodontic aligner. The method further includes making a comparison of the probability that the orthodontic aligner associated with the digital design will be damaged during manufacturing of the orthodontic aligner to a probability threshold and determining whether the orthodontic aligner is a high risk orthodontic aligner based on a result of the comparison. Responsive to determining that the orthodontic aligner is a high risk orthodontic aligner, the method includes performing at least one of a) a corrective action or b) selecting a manufacturing flow for high risk orthodontic aligners.
