An insert is removably received in a channel of an orthodontic appliance. The insert substantially prevents sections of the appliance from moving toward each other a distance that would otherwise be sufficient for debonding the appliance from the associated tooth. The insert may be used with the appliance alone, or in combination with the appliance and a positioning tray. The insert may also be advantageously employed during manufacture, shipping, patient set-up or other handling, and may also be used in the course of treatment. Additionally, the insert may be provided with structure for serving as a positioning jig.