True allergy to polyurethane is extremely rare. Localised irritation is almost always an ulcer or a pressure point. What matters clinically is whether the reaction is localised or widespread.
One tooth, or one area of the palate, is almost certainly an ulcer or pressure sore. Advise the patient to keep wearing the aligner, apply a topical gel and monitor it.
A reaction across all the mucosa in contact with the aligner, in a contact dermatitis pattern, is different. Remove the aligner, examine the patient, and tell us with your clinical notes so it can be reviewed urgently.
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If this article did not resolve your question, your practice manager is your first point of contact for case and product support. For anything that needs a tracked outcome, start a chat with the OneSmile Concierge using the chat button on this page. Include the patient name, the case number and the current aligner number so it can be actioned without a follow-up question.