Embroidery Troubleshooting – FAQ

Gaps Between Outlines and Fills

Why it happens: Inside stitches can pull inward, leaving a gap along the outline.

Fixes:

  • Use stronger or additional stabilizer (adhesive backing + poly-mesh cut-away).
  • If editable, add underlay and apply pull compensation.

Satin Columns Look Too Narrow

Why it happens: Fabric and stitches are pulling in.

Fixes:

  • Add more or stronger stabilizer.
  • Widen columns in software (if editable).
  • Check top and bobbin thread tensions.

Underlay Showing Outside the Columns

Why it happens: Loose tension, long underlay stitches, or narrow satin.

Fixes:

  • Use stronger stabilizer (cut-away or layered).
  • Shorten underlay stitch length.
  • Widen satin stitch columns.
  • Add water-soluble topping if needed.

See-Through Stitch Coverage

Why it happens: Stitch density is too light.

Fixes:

  • Use thicker thread (30WT instead of 40WT).
  • Reduce design size slightly to increase density.
  • Place matching fabric or stabilizer underneath.

Stitching Feels Stiff or Heavy

Why it happens: Density is too high.

Fixes:

  • Use lighter/thinner thread.
  • Slightly increase the design size.

Fabric Puckering or Buckling

Why it happens: Too many stitches or short stitch length for the fabric.

Fixes:

  • Increase design size by 10–15%.
  • Use adhesive stabilizer with poly-mesh cut-away (especially on knits).

Thread Nests Underneath (“Birdnesting”)

Why it happens: Incorrect threading, damaged needle, or dry environment.

Fixes:

  • Re-thread the machine carefully.
  • Replace the needle.
  • Raise humidity in your sewing room (25–30%).

Top Stitches Looping or Loose

Why it happens: Damaged needle, wrong needle size, or tension problems.

Fixes:

  • Replace the needle.
  • Check top and bobbin tension.
  • Verify bobbin is correctly inserted.

Bobbin Thread Showing at the Edges

Why it happens: Lint build-up or tension imbalance.

Fixes:

  • Clean the bobbin area.
  • Adjust tension: top not too tight, bobbin not too loose.
  • Correct balance = about 1/3 bobbin thread visible on the back.

Bobbin Thread Pulling to the Top

Why it happens: Top tension is too tight.

Fixes:

  • Loosen top tension slightly.
  • Re-thread and clean thread path.

Tiny Lettering or Details Not Clear

  • Use thinner thread (50WT or 60WT).
  • Use a smaller needle.

Tiny Holes Near Stitches

Why it happens: Excess density or wrong needle type.

Fixes:

  • Slightly enlarge the design or use lighter thread.
  • On knits/delicates, switch to a ballpoint needle.

Fabric “Flagging” (Bouncing with the Needle)

Why it happens: Bent needle or loose hooping.

Fixes:

  • Replace the needle.
  • Re-hoop fabric so it’s taut like a drum.

Wrinkles from Hooping

Why it happens: Hoop too tight or inserted unevenly.

Fixes:

  • Insert hoop evenly, screw side first.
  • Avoid over-tightening.

Hoop Burn (Ring Marks)

  • Spray lightly with sizing, then brush or wipe fabric.
  • Prevent by taping hoop rings or hooping with tear-away.
  • Use adhesive or magnetic hoops for sensitive fabrics.

Thread Fraying or Breaking

Why it happens: Damaged needle, poor threading, or brittle thread.

Fixes:

  • Replace the needle.
  • Try a different spool of thread.
  • Slow machine speed for metallics or small lettering.

Stitches Show in Software but Don’t Sew

Why it happens: Satin columns too wide for some machines.

Fixes:

  • Reduce design size slightly.
  • Convert satin to fill stitch if possible.

Wrong Thread Colors

Why it happens: File formats often save only color stops, not true colors.

Fixes:

  • Adjust colors in embroidery software and re-save.
  • Use the provided color chart as reference.
  • For single-needle: line up thread cones in order.

File Not Recognized by Machine/Software

Why it happens: File too big, not centered, or in the wrong format.

Fixes:

  • Check that the design fits your machine’s sewing area.
  • Re-center the design.
  • Convert/re-export to the correct format.

Finished Embroidery Looks Messy

Fixes:

  • Keep as a test piece for future reference.
  • Snip bobbin threads from the back and brush away top threads.
  • Lift knots with a pin before snipping.
  • For dense areas, use a stitch eraser or razor carefully.