A method and system for making an orthodontic aligner, as well as an orthodontic aligner. The method comprising: determining at least one super contact region between upper teeth and lower teeth of a subject, the super contact region comprising identifying an area around an at least one contact region between the upper teeth and the lower teeth which exceeds a predetermined magnitude of contact between the upper and lower teeth during a predefined upper/lower teeth position； and generating a digital model of the aligner comprising applying the determined super contact region to a digital model of a pre-form aligner such that a thickness of the aligner body at the determined super contact region is less than a thickness of the aligner body at regions which are not determined super contact regions.
