Why Doesn't Invisalign Smooth the Tray Edges?

We periodically have a problem with sharp trays but it has been minor, and we have always been able to smooth the border with an emery board.  If the borders of multiple trays are extremely rough there may be a manufacturing problem or a distorted impression may have caused an incorrect set of trays to be created.  Talk to your dentist and have him call Invisalign to trouble shoot.  They have always been very concerned and helpful in fixing any problems.  They really seem to care about their product.  

We definitely hear that the edges of the aligners can be slightly uncomfortable for out patients.  The issue is that if they are rounded off, they would likely have to be thicker.  Due to the angles at which pressure may need to be applied, the aligners may not be sitting right up against the teeth at the start of an aligner, but may change position as the teeth move.  No matter what, so long as there is some kind of step between the gums, teeth, and aligner, you will likely feel the edge.  It is important that the aligners don't sit right on the gums as to not cause gum recession.

The best way to deal with sharp aligners is to get a clean nail file and smooth out some of the rough edges.  This usually takes care of the problem without compromising any tooth movement  If you have concerns with this, please speak to your orthodontist.