Abstract Background Thermoplastic materials, such as glycol-modified polyethylene terephthalate (PET-G) and thermoplastic polyurethane (TPU), undergo alterations due to environmental factors in the oral cavity, which can affect their composition and surface properties over time. While previous studies have explored these changes, a comprehensive characterization of TPU and PET-G properties, particularly after immersion in artificial saliva, remains limited. This study aimed to evaluate the aging process of 24 TPU and 24 PET-G dumbbell-shaped specimens before and after exposure to artificial saliva. The analysis focused on the morphological, chemical, and optical properties of the samples, including thickness, weight, and surface roughness. Methods The study examined 48 thermoplastic samples, equally divided between PET-G and TPU. The samples were thermoformed into standardized shapes and analyzed at three time points: after thermoforming (T0), after 7 days (T1), and after 14 days (T2) of immersion in artificial saliva at 37 °C. Measurements included weight, thickness, surface roughness, absorbance, and Fourier transform infrared spectroscopy (FTIR). Data were analyzed using one-way ANOVA to identify significant changes over time, with a significance level of p 0.01). The roughness disparity between TPU and PET-G persisted even after immersion in saliva. Conclusions Following the simulated intraoral aging process, significant changes in surface roughness were observed in TPU and PET-G specimens. The reduction in roughness, particularly a 39.27% decline in PET-G and 23.02% in TPU, has been clinically associated with decreased plaque accumulation and reduced friction between the aligner and the teeth.