PETG vs. TPU Aligner Sheets: Which Material Fits Your Machine? -

PETG vs. TPU Aligner Sheets: Which Material Fits Your Machine?

Ever wonder why some dental aligners crack like thin ice while others stay crystal clear and firm for weeks?

It’s not magic, it’s material science.

You’re probably sitting there with a high-end vacuum forming machine, wondering why your PETG sheets are bubbling or why your TPU isn’t hugging the molars.

I’ve been in the dental supply game long enough to know that choosing between PETG and TPU isn’t about “better”—it’s about “fit”.

If you pick the wrong material for your specific machine, you’re just burning cash.

Let’s break it down, no fluff, just the facts.

The PETG Reality: The Workhorse

ETG is the industry standard for a reason: it’s predictable. It’s rigid, it’s clear, and it’s cheap.

Best for: Standard retainers and basic aligners.
The Win: It heats up fast and forms accurately with almost any Dental Vacuum Forming Machine.
The Catch: It’s brittle; if the patient is a “grinder,” that aligner is toast.
Pro Tip: Check out our PETG Dental Thermoforming Sheets if you want high-clarity results without the premium price tag.

The TPU Reality: The Premium Flex

TPU is the new school. It’s flexible, tough, and way more comfortable for the patient.

Best for: Complex orthodontic cases and long-term wear.
The Win: It doesn’t snap. It applies constant, gentle force.
The Catch: It’s finicky; you need a machine with serious suction or precise temp control.
Pro Tip: If you’re running a high-end lab, our Dental Teeth Aligner Sheets provide that “premium” feel that justifies a higher price point.

The Comparison Matrix: Pick Your Poison

Feature	PETG Sheets	TPU Sheets
Clarity	Excellent	Good
Flexibility	Rigid	High
Durability	Moderate	Superior
Cost	Budget-friendly	Premium

How to Match Material to Your Machine

If you’ve got a basic tabletop unit, stick with PETG. TPU requires a level of precision that cheap heaters just can’t hit. I’ve seen guys try to run TPU on an old machine and end up with a mess of wasted sheets. If you are running an industrial-grade precision setup or high-end automated thermoforming systems, choose TPU. It handles the pressure and gives you a product you can charge double for.

Common Worries (FAQs)

Why is my PETG bubbling? It’s moisture. PETG is like a sponge; keep it in a vacuum-sealed bag or it’s ruined.

Is TPU worth the extra cost? If you want fewer remakes and happier patients, yes. If you’re doing high-volume, low-cost retainers, no.

Can I use the same settings for both? No. TPU usually needs a bit more “soak” time in the heat. Test a few sheets first.

What thickness should I buy? 0.8mm for aligners, 1.0mm or 1.5mm for retainers. Don’t overthink it.

At the end of the day, you need a supplier who actually stocks the stuff and knows the difference.

Stop guessing which PETG vs TPU Aligner Sheets will work and just ask us for a sample pack to test on your own machine.