Fraying & Breaking Thread

Why Does My Thread Break or Fray?

Embroidery thread is a critical component of any successful embroidery project. Unfortunately, one of the biggest frustrations for embroiderers is when the thread keeps breaking.

 Let’s look at the reasons why embroidery thread might keep breaking or fraying, and what can be done to reduce the risk of this happening. It should be noted first and foremost that thread breaks and frays are separate issues. Thread breaks are usually caused by tension issues, thread path interference, old thread or poor digitizing. Thread frays have more to do with burrs and nicks in the thread path.

Top 5 Questions to Ask

1. Is the machine threaded properly? Try re-threading according to your machine manual. (Breaking)

2. Is the tension too tight? If the tension settings are too tight on your machine, then this can put too much strain on the thread, leading it to snapping. Is the top tension too tight? Use the 1/3 - 1/3 - 1/3 rule. (Breaking)

3. Is this related to the needle?

a. Have you changed the needle recently? On average, the lifespan of a machine embroidery needle is about 8 hours of running time. A damaged needle may or may not be visible to the naked eye. (Fraying)

b. Are you using the correct size needle based on the thread you are using? (Fraying) Check out this Quick Reference Needle Guide.pdf to make sure you are running smooth

c. Is the needle inserted properly? Is the needle eye facing forward? Is it inserted fully? (Breaking and Fraying)

4. Has the machine been lubricated? Be sure to follow your machine manual’s suggested lubrication schedule for your machine. (Breaking)

5. Is the bobbin case tension spring clear of lint? Run a business card underneath the tension plate to clear out any lint build up. (Breaking)

Additional Causes of Thread Breaks and Frays

6. Check for burrs and nicks in the following areas: (Fraying)

 a. Rotary hook

 b. Thread path

 c. Needle eye

 d. Throat plate

 e. Bobbin case

7. Is the pressure foot nicked, burred or bent? Check with your machine manual or contact your machine tech.(Fraying and Breaking)

8. Is the needle going through the center of the pressure foot? Check with your machine manual or contact your machine tech. (Fraying and Breaking)

9. Is the needle going through the center of the needle throat plate? Check with your machine manual or contact your machine tech. (Fraying and Breaking)

10. Are you using bad quality thread? Make sure you are using high-quality thread and not old weak Rayon thread, which is sometimes referred to as “old style” rayon.

11. How has the thread been stored? How old is the thread? Old, improperly stored thread will break down and deteriorate. (Breaking) Embroidery thread should be stored in cool, dry conditions away from excessive light. Look at our thread storage options to ensure this doesn’t happen moving forward.

Is the thread breaking on more than 1 needle (on the same head)?

1. Check the bobbin/rotary hook area

a. Is the bobbin threaded correctly?

 b. Is the rotary hook area clean?

 c. Has it been lubricated?

 d. Does the throat plate have any rough spots in the needle hole area?

 e. Is the outside of the rotary hook area smooth?

 f. If you wind your own bobbins, are they wound correctly?

Other possible causes of thread breaks:

• Machine speed is too fast – try slowing the machine down.

• Build up of adhesive sprays and glues on the needle – use needle-friendly adhesives and glues. Be sure to allow them to dry adequately before embroidering.
• Incorrect needle depth – Check your machine manual or contact your technician.
• Improper hooping – both too loose and too tight hooping can cause stress on the needle and thread and can cause thread breaks.
• Rough/abrasive backing – Use a high quality backing that is intended for embroidery.

• Stick-On backing – The adhesive can break down due to improper storage, high heat and humid conditions. Be sure you are using needle-friendly Stick-On backings that are not old and have been stored properly.
• No backing or wrong backing being used – always use a backing, even if the fabric is stable enough to support the embroidery without it. Backing allows the hoop to glide smoothly over the needle plate and cylinder arm.
• Too heavy a bobbin thread – use of the proper bobbin thread will ensure the best balance between the top thread and bobbin thread.
• Poor digitizing – This can also be a major contributor to frequent thread breaks; if errors have been made during digitizing or if patterns are needlessly complex then it puts unnecessary strain on the machine
• Machine timing is off – If your machine's timing is off by even a fraction of a second, then this will result in skipped stitches or broken threads due to improper hooking motions 

By taking all these factors into account you should be able to greatly reduce instances of snapped threads ruining projects - ensuring smoother running operations and higher quality results!