Many things on an embroidery machine can cause thread breaks, but not all are obvious.

BACKING - Excessive backing material used by inexperienced operators can cause thread breaks. If an operator uses three to four sheets of backing, stiffer embroidery is the result, but it also applies a great deal of friction to the needle, causing thread breaks. Needle drag is when backing is too thick and rigid; it normally is abrasive or adhesive, causing "drag" on the needle. The needle overheats and con...
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