Embroidery thread breaking during sewing is a common and frustrating problem. It can stop your project, mess up your design, and waste thread. Usually, thread breaks happen because of a few main reasons: something is wrong with the machine settings, like the embroidery machine thread tension; the supplies you are using, such as a dull embroidery needle or poor quality embroidery thread; or your machine needs care, maybe the embroidery machine needs cleaning. Sometimes, the issue is with the preparation, like using the wrong stabilizer for embroidery or incorrect embroidery needle size. Let’s figure out what’s causing your thread trouble and how to fix it.
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Grasping Why Thread Breaks
Thread does not just break for no reason. It breaks when it is put under too much stress. This stress can come from many places. The thread runs through many parts of the machine. It rubs against metal, bends around corners, and passes through the needle eye very fast. If anything is wrong along this path, the thread can weaken and snap. Knowing the common causes helps you find the fix.
Inspecting Your Thread and Supplies
The thread you use matters a lot. Cheap or old thread can break easily.
Spotting Poor Quality Embroidery Thread
Not all threads are made the same. Poor quality embroidery thread might have thin spots. It might be fuzzy or not twisted tightly. This makes it weak.
- How to check thread quality:
- Hold a length of thread up to the light. Does it look smooth? Are there fuzzy parts?
- Try to snap a piece by hand. Good thread should take a little pull to break. If it snaps with almost no effort, it is probably weak.
- Look at how it unwinds from the spool. Does it twist or tangle easily?
Using good thread is the first step to avoiding breaks. Choose thread from a well-known brand. These threads are made to be strong and smooth for machines.
Is Your Thread Old?
Thread can get old. Over time, it can dry out or lose its strength. Old thread stored in hot or sunny places is more likely to break.
- Check older thread: If you have thread that is many years old, it might be the problem. Try a fresh spool of new thread from a good brand. See if the breaking stops.
Picking the Right Needle
The needle is one of the most common reasons for thread breaks. The needle does a lot of work. It pokes holes in the fabric, guides the thread through the fabric, and forms loops for the bobbin thread. A bad needle will cause problems.
Identifying a Dull Embroidery Needle
A dull embroidery needle does not make a clean hole in the fabric. Instead, it pushes fabric fibers aside or tears them. This creates friction. The thread rubs against the fabric fibers and the rough edges of the needle’s eye. This friction heats up the thread and weakens it, causing it to snap.
- Signs of a dull needle:
- You hear a popping sound when the needle goes into the fabric. This means it is breaking fibers instead of sliding through them.
- The needle looks dark or has a rough tip when you look closely. A good needle is shiny and sharp.
- The fabric might look slightly damaged around the stitches.
It is a good idea to change your needle often. Many people change needles for each new project or after sewing for about 8-10 hours. Needles are cheap compared to the frustration of broken thread.
Choosing the Correct Embroidery Needle Size
Using the wrong embroidery needle size can also cause breaks. The size of the needle needs to match the thread size and the fabric type.
- Needle size too small: If the needle eye is too small for the thread, the thread will rub hard against the edges of the eye as it moves up and down. This friction causes heat and wear, leading to breaks.
- Needle size too large: If the needle is too big for the fabric, it makes a hole that is too large. This does not support the thread correctly as it passes through the fabric. It can also damage delicate fabrics.
Common Needle Types and Sizes for Embroidery:
| Needle Type | Common Sizes | Use Case | Why Size Matters |
|---|---|---|---|
| Embroidery | 75/11, 80/12, 90/14 | Rayon, Polyester, Cotton embroidery threads | Has a larger eye and a special scarf to protect fragile threads |
| Sharp/Microtex | 60/8 to 80/12 | Fine fabrics, silks, microfibers | Creates a very clean hole |
| Universal | 70/10 to 90/14 | General use, knit and woven fabrics | Less ideal for embroidery threads due to smaller eye |
For most machine embroidery, an Embroidery needle (like a 75/11 or 80/12) is best. Its design helps protect the thread. Match the needle size to your thread weight (thicker thread needs a bigger needle) and fabric.
Examining Machine Settings: Tension is Key
Embroidery machine thread tension is one of the biggest causes of thread breaking. Tension is how tight or loose the thread is as it feeds through the machine. There is upper thread tension and embroidery bobbin tension. Both must be set correctly.
Adjusting Upper Thread Tension Embroidery Machine
The upper thread tension embroidery machine controls how the thread from the top spool pulls through the machine and interacts with the bobbin thread. If it’s too tight, the thread is constantly under too much pull. This stretches and weakens it until it breaks.
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Signs of upper tension being too tight:
- The bobbin thread shows on the top of the fabric.
- The top thread looks very straight on the back of the fabric instead of meeting the bobbin thread in the middle.
- You hear a popping sound as the needle pulls the top thread through.
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How to check and adjust upper tension:
- First, make sure the thread is correctly threaded through the machine, especially through the tension discs. Even a slight mistake here can cause problems.
- Test stitch on a scrap of fabric with your stabilizer. Look at the stitches on both the top and bottom.
- Ideally, the top thread and bobbin thread should meet in the middle layers of the fabric.
- If the bobbin thread is visible on top, the upper tension is too tight. Lower the upper tension setting (usually turn a dial to a smaller number or use machine controls).
- If the top thread is visible on the bottom, the upper tension is too loose. Raise the upper tension setting.
- Make small adjustments. Change the setting by a little bit, stitch again, and check. Repeat until the tension looks right.
Checking Embroidery Bobbin Tension
The embroidery bobbin tension is also important. It controls how the bobbin thread comes up to meet the top thread. This tension is set in the bobbin case. It is less common to need to adjust bobbin tension often, but it can be a reason for thread breaks.
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Signs of bobbin tension being too tight:
- The top thread is pulled down to the back of the fabric.
- The top thread breaks often.
- Stitches look puckered on top.
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Signs of bobbin tension being too loose:
- Loops of bobbin thread show on the back of the fabric.
- Top thread looks flat on the bottom.
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How to check bobbin tension (Drop Test – for most machines):
- Take the bobbin case out of the machine with a full bobbin in it.
- Hold the thread tail of the bobbin. Let the bobbin case hang.
- Give the thread a gentle little tug or bounce.
- The bobbin case should slowly drop about an inch or two and then stop.
- If it drops freely to the floor, it is too loose.
- If it does not drop at all, it is too tight.
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Adjusting bobbin tension: There is a small screw on the bobbin case. Use a very small screwdriver.
- Turn the screw a tiny amount (like 1/8th of a turn).
- Turn clockwise to make tension tighter.
- Turn counter-clockwise to make tension looser.
- Be very careful and make tiny changes. It is easy to mess up the bobbin case tension. Mark the original position of the screw with a pen before you start if you are unsure.
- Some embroiderers use a second bobbin case just for embroidery to avoid changing their regular sewing bobbin tension.
Balancing the upper thread tension embroidery machine and embroidery bobbin tension is key for smooth stitching and preventing breaks.
Does Your Machine Need Care?
Like any tool, an embroidery machine needs cleaning and oiling to work right. Dirt, lint, and old oil can cause thread breaks.
When the Embroidery Machine Needs Cleaning
Lint and small bits of thread build up inside the machine, especially around the bobbin area, tension discs, and needle bar. This buildup creates friction.
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How dirt causes breaks:
- Lint packed in the bobbin case area can snag the bobbin thread.
- Dirt in the upper tension discs can make the tension uneven or too tight.
- Grit around the needle bar can cause the thread path to be rough.
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Cleaning your machine:
- Use a small brush (often came with your machine) to remove lint from the bobbin area.
- Use tweezers to pull out stubborn bits of thread or lint.
- Clean around the needle plate (you might need to remove it).
- Check your machine manual for where to oil. Put just one drop of oil in the right spots. Too much oil can attract more lint.
- Clean the tension discs. You can do this by raising the presser foot (which opens the discs) and running a piece of dental floss or a thin strip of lint-free cloth through them.
A clean and oiled machine runs smoother. This means less stress on the thread. Regular cleaning is part of machine embroidery troubleshooting.
Considering Fabric and Stabilizer
The fabric you embroider on and the stabilizer for embroidery you use play a big role in how the machine and thread behave.
Choosing the Right Stabilizer for Embroidery
Stabilizer for embroidery gives the fabric body and keeps it from stretching or puckering while you stitch. If you use the wrong type or not enough stabilizer, the fabric can move or bounce with the needle.
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How wrong stabilizer causes breaks:
- If the fabric is not held firmly, it can push up with the needle. This makes the thread pull harder to get through, causing stress.
- Thin fabric without enough support can get damaged by the needle, creating rough spots the thread catches on.
- Sticky stabilizers that get stuck to the needle can make the needle sticky and grab the thread incorrectly.
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Using the right stabilizer:
- Match the stabilizer type and weight to your fabric and the stitch count of your design.
- Light, sheer fabrics need a gentle stabilizer.
- Stretchy fabrics like knits need good support, often a cut-away or heavy tear-away.
- Designs with lots of stitches need more stable support than simple outlines.
- Hoop the fabric and stabilizer together correctly. Make sure they are smooth and taut like a drumhead, but not stretched out of shape.
The proper stabilizer for embroidery provides a stable base, allowing the needle to pass through cleanly and the thread to form stitches without excessive pull.
Other Potential Causes for Thread Breaks
Beyond the main issues, several other things can cause thread to snap.
The Way the Thread Unwinds
How the thread comes off the spool or cone matters.
- Thread stand: Some machines work better with a thread stand, especially for large cones of thread. This helps the thread feed straight up and then smoothly into the machine’s thread path.
- Spool direction: For cross-wound cones (thread goes across diagonally), use a horizontal spool pin or a thread stand. For stack-wound spools (thread goes straight up and down), use a vertical spool pin. If the thread has to pull off the end of a horizontally placed stack-wound spool, it can twist and snag.
Issues with the Thread Path
The thread travels through guides and tension discs before the needle. If there is anything wrong along this path, the thread can break.
- Incorrect threading: Check your machine manual and re-thread your machine carefully. Even missing one guide can cause tension problems.
- Damaged guides: Check if any thread guides or the eye of the needle plate are nicked or rough. These rough spots can snag the thread. If you find damage, you might need a service visit or a replacement part.
- Thread tangling: If the thread tangles on the spool pin, catches on the edge of the spool, or gets caught under the spool cap, it will cause sudden tension and break.
Machine Speed
Running your machine too fast, especially with complex designs or delicate threads, can cause breaks. The thread is working harder and heating up faster. Try slowing down the machine speed.
Design Issues
Sometimes, the embroidery design itself can stress the thread.
- High stitch density: Designs with many stitches packed tightly together put a lot of stress on the needle and thread as they repeatedly go through the same small area.
- Underlay stitches: Sometimes the underlay stitches (the stitches that lay down first to prepare the fabric) are too dense or too close to the edge. This can make the area too stiff or create bumps that snag the needle and thread.
If you suspect the design, try stitching a different design or a simpler part of the same design. You might need to edit the design to reduce density if your software allows.
Machine Embroidery Troubleshooting Steps
When your thread keeps breaking, follow a step-by-step approach to find the cause. This is key to machine embroidery troubleshooting.
A Process for Fixing Broken Embroidery Thread
Don’t just keep re-threading and trying again. Stop and check things in order. This helps you find the real problem quickly. This is how you go about fixing broken embroidery thread.
- Stop and Clear: When the thread breaks, stop the machine. Pull the broken thread out of the machine. Remove any tiny bits of thread left in the stitch area or machine.
- Re-thread: Re-thread the upper thread path completely. Make sure the presser foot is up when you thread so the thread seats correctly in the tension discs.
- Check Bobbin: Take out the bobbin and bobbin case. Check for any tangled thread, lint, or damage. Put the bobbin case back in correctly. Check the bobbin is spinning freely.
- Change Needle: Put in a brand new needle of the correct type and size for your fabric and thread. Make sure it is inserted correctly and pushed all the way up.
- Check Thread: Try using a fresh spool of high-quality thread. Make sure the thread is coming off the spool or cone smoothly.
- Check Tension: Stitch a test on scrap fabric with stabilizer. Look at the stitches. Adjust upper thread tension embroidery machine slightly if needed. Do NOT change bobbin tension unless you suspect it is the issue AND you know how to do the drop test.
- Clean Machine: Give your machine a quick clean, especially around the bobbin area and the needle bar.
- Check Stabilizer and Hooping: Is the fabric properly stabilized? Is it hooped tightly but without stretching? Is the hoop secure on the machine?
- Slow Down: If the design is complex or has high stitch density, reduce the machine speed.
- Consider Design: If the issue started with a specific design, stitch a simple built-in design to see if the problem goes away.
By going through these steps, you systematically rule out common causes. This process is the core of effective machine embroidery troubleshooting.
Table: Quick Troubleshooting Checklist
| Problem Sign | Possible Cause | Check/Fix | Related LSI Keyword |
|---|---|---|---|
| Thread keeps snapping | Poor quality embroidery thread | Try new, good quality thread. | Poor quality embroidery thread |
| Snapping, skipped stitches | Dull embroidery needle | Change to a new, sharp needle. | Dull embroidery needle |
| Snapping, bobbin thread shows on top | Upper thread tension embroidery machine too tight | Lower upper tension setting slightly. | Upper thread tension embroidery machine |
| Snapping, top thread shows on bottom | Upper thread tension too loose | Raise upper tension setting slightly. | Upper thread tension embroidery machine |
| Snapping, top thread pulled to back | Embroidery bobbin tension too tight | Carefully loosen bobbin screw a tiny bit. Use drop test. | Embroidery bobbin tension |
| Snapping, wrong stitch look | Incorrect embroidery needle size | Use correct needle type/size for thread and fabric. | Embroidery needle size |
| Snapping, fabric puckering/moving | Wrong stabilizer for embroidery | Use correct stabilizer type and weight. Hoop correctly. | Stabilizer for embroidery |
| Snapping, lots of lint/noise | Embroidery machine needs cleaning | Clean and oil machine according to manual. | Embroidery machine needs cleaning |
| Snapping, random or machine jams | General machine issue, threading error | Re-thread machine completely. Check thread path. Follow machine embroidery troubleshooting. | Machine embroidery troubleshooting |
| Snapping when starting stitch | Thread caught, machine issue | Check threading, spool position. Try slowing start speed. | Fixing broken embroidery thread |
Fixing Broken Stitches
When thread breaks mid-design, you often need to fix the stitches that were missed.
Steps for Fixing Broken Embroidery Thread
- Stop the machine: As soon as it breaks.
- Note where it stopped: Look at the design on the machine screen or the fabric to see the last good stitch area.
- Trim loose threads: Carefully trim the broken ends of the top and bobbin threads close to the fabric surface.
- Re-thread: Fix the cause of the break and re-thread the machine.
- Return to the break point: Use your machine’s stitch-back feature or navigation to move the needle position back a few stitches from where the break happened. This lets you sew over the last few good stitches to secure them.
- Resume stitching: Start the machine slowly and watch as it stitches over the old stitches and continues the design.
- Check the fix: After the design is done, check the repaired area. You might need tweezers to gently pull out any small bits of old thread caught under new stitches.
Fixing broken embroidery thread takes patience, but going back a few stitches usually makes the repair almost invisible.
Preventing Future Thread Breaks
Once you solve your current thread breaking issue, take steps to prevent it from happening again.
- Regular Maintenance: Clean and oil your machine often. Follow your machine’s manual for how and when.
- Fresh Needles: Get into the habit of changing your needle for each new project or after a set number of stitching hours.
- Quality Supplies: Use high-quality threads and stabilizers from reputable brands.
- Test Stitch: Always do a test stitch on a scrap of your fabric with the same stabilizer before starting the real project. Check tension and stitch quality.
- Correct Threading: Double-check that your machine is threaded correctly every time you start.
- Optimal Speed: Don’t always stitch at top speed. Find a speed that works well for your machine, thread, and design.
- Proper Storage: Store your threads away from direct sunlight, heat, and moisture.
By taking these steps, you reduce the chances of thread breaks and make your embroidery experience much smoother.
Frequently Asked Questions
Why is my embroidery thread breaking only on certain designs?
This often points to an issue with the design itself. It might have high stitch density in certain areas, too much underlay, or colors that jump around a lot, causing many tie-offs and trims. Try reducing the design speed or checking the design properties in your software if possible. Stitching a simple design will help confirm if the issue is the design or the machine.
Can using different thread types cause breaks?
Yes. Some threads, like metallic threads or older rayon threads, can be more fragile than polyester. You often need special needles (like metallic or embroidery needles with larger eyes), lower machine speed, and proper tension settings when working with these threads.
Does humidity affect embroidery thread?
Yes, extreme humidity or dryness can affect thread strength. Storing thread in a stable environment is best. Very dry thread can become brittle.
My machine was just serviced, and now the thread is breaking. Why?
This could be a new issue introduced during service (maybe tension wasn’t reset right, or something wasn’t put back perfectly). Or, it could be that the problem was always there, but you notice it more now. Double-check your own setup first (threading, needle, thread) and if problems continue, contact the service technician.
How do I know if my bobbin tension is the problem?
The drop test (explained earlier) is a good way to check bobbin tension. Also, observing your stitches can help. If the top thread is being pulled excessively to the back of the fabric, or if you have random top thread breaks even with correct upper tension, the bobbin tension might be too tight.
Solving the mystery of why your embroidery thread keeps breaking usually comes down to checking the basics: thread quality, needle condition and size, tension settings (both upper and bobbin), machine cleanliness, and stabilizer use. By systematically checking these areas, you can fix the problem and get back to enjoying your embroidery projects. Good luck!