Solutions to Common Sewing Problems

Problem

Causes

Solutions

Upper Thread Breaks

 

 

  • Incorrect threading
  • Knots or twists in thread
  • Tension too tight
  • Damaged/old needle
  • Needle too small
  • Re-thread machine properly
  • Replace thread
  • Reset bobbin and top thread tension
  • Replace needle
  • Use correct needle for thread and application

Bobbin Thread Breaks
  • Bobbin case incorrectly threaded
  • Bobbin case incorrectly inserted
  • Bobbin does not turn smoothly in bobbin case
  • Lint in bobbin case
  • Bobbin tension too tight
  • Remove bobbin and re-thread with bobbin turning clockwise
  • Remove and re-insert bobbin case
  • Check that bobbin case and bobbin are in “round”; replace if necessary
  • Clean bobbin case and surrounding machine area
  • Check and reset bobbin tension

Skipped Stitches
  • Thread tension too tight
  • Needle damaged
  • Needle wrong size
  • Sewing machine out of adjustment
  • Reset top and bobbin tension
  • Replace needle
  • Use correct needle size
  • Have sewing machine adjusted for timing; hook to needle clearance; needle bar height

Frayed Stitches
  • Needle too small
  • Tension too tight
  • Damaged thread
  • Increase needle size
  • Reset tension
  • Replace thread

Thread Loops on Bottom
  • Thread not in top tension
  • Machine incorrectly threaded
  • Top tension too loose
  • Burr on hook mechanism
  • Re-thread machine with presser foot “up”
  • Re-thread machine incorporating take-up lever
  • Reset top tension
  • Remove burr

Irregular Stitches or Malformed Stitched
  • Wrong needle size
  • Incorrect threading
  • Upper tension too loose
  • Operator pulling fabric
  • Bobbin wound unevenly
  • Ensure correct needle for fabric & thread
  • Unthread machine and carefully re-thread
  • Reset lower and upper thread tension
  • Check presser foot pressure
  • Rewind bobbin

Fabric Puckers
  • Excessive stitch length
  • Needle point is blunt
  • Excessive thread tension
  • Fabric is too soft
  • Thread displacement – too much thread in a small area
  • Fabric not feeding
  • Decrease stitch length
  • Change needle often
  • Check bobbin and upper tension
  • Use stabilizer
  • Decrease field density; scale embroidery designs; increase stitch length
  • Check presser foot, needle plate, feed dogs
     

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