Embodiments relate to an aligner breakage solution. A method includes obtaining a digital design of a polymeric aligner for a dental arch of a patient. The polymeric aligner is shaped to apply forces to teeth of the dental arch. The method also includes performing an analysis on the digital design of the polymeric aligner using at least one of a) a trained machine learning model, b) a numerical simulation, c) a geometry evaluator or d) a rules engine. The method may also include determining, based on the analysis, whether the digital design of the polymeric aligner includes probable points of damage, wherein for a probable point of damage there is a threshold probability that breakage, deformation, or warpage will occur. The method may also include, responsive to determining that the digital design of the polymeric aligner comprises probable points of damage, performing corrective actions based on the probable points of damage.
