It almost looks like it's rotated backwards from the left side, it's absurd.

My left side is definitely better though.

1. As the palate drops down and flattens (from its vaulted shape) with expansion, the top of the expander contacts the palate and sits lower in the upper jaw than it should
2. As the palate expands, the teeth and gums may move around. This will cause the expander to perhaps dig into the gums or push against teeth uncomfortably

The good news: The acrylic on the expanders can be easily sanded/shaved down with minimal effort. With the expander in your mouth, use your fingers to locate where the expander acrylic has excess material and then sand away at that area. You do not need to worry about shaving too much, just keep sanding it and putting it back into your mouth until you feel that the hard part causing the issue has been sanded away. 

Even the file on a nail clipper is sufficient to wear the material down quite easily. I recommend using a metal file over something like sandpaper in order to prevent roughness on the surface of the acrylic which both causes discomfort and harbours bacteria.

Be sure to wash off the acrylic dust before putting it back in your mouth! You should get significantly more mileage out of the expander like this. 

This is great, thank you! How do you shave it down? I've tried using sandpaper, but it doesn't work? Would a grinder with a diamond type attachment work better?

How many mm do you suggest the palate drops? My BioBloc is fitting terribly at the moment, and I'm feeling pressure in all the wrong places - in my nasal bridge, and pressure on my teeth - both of which were not there before. It was almost passive, I didn't notice it. So I'm assuming that at the 3mm expansion mark, perhaps my palate dropped a bit? Impossible to know I guess unless I have a side by side scan, which are expensive, and I don't really need I feel.

Has anyone had to get a second palate expander through their treatment? Wondering how many expanders would typically be used over the duration of treatment, and is this the same for children going through expansion?

With the method explained in this forum would it be possible to improve, even slightly, the eye area? Or is surgery necessary?