Embroidery Machine Thread Keeps Breaking - How to Fix It

It sounds obvious, but the thread is always worth checking first.

• Make sure you're using good quality embroidery thread - cheap or old thread is brittle and prone to breaking
• Check the thread isn't old or degraded - thread that has been sitting on the spool for years loses its strength and flexibility
• Make sure you're using embroidery thread, not standard sewing thread - they behave very differently under the speed and tension of embroidery

Incorrect threading is one of the most common causes of thread breaking in embroidery. Even if you've already re-threaded a few times, it's worth going through it again slowly and patiently - referring to your manual rather than going from memory.

• Raise the presser foot before re-threading so the tension discs open properly
• Follow your machine's threading path carefully, making sure the thread passes through every guide, tension disc and the take-up lever in the correct order
• Even missing one small guide can cause the thread to snap repeatedly

If the thread is catching or snagging on its way to the machine, it will break under the tension of embroidery, even if everything else is set up correctly.

• Make sure the thread is unwinding smoothly and isn't catching, snagging or getting wrapped around the spool pin
• Check the spool is sitting correctly and the thread is feeding off evenly - if it unwinds in the wrong direction, it will create resistance and snap
• Make sure you're using the correct spool cap for your thread size

A dull, bent or wrong needle is one of the most common causes of thread breaking in embroidery and one of the easiest to fix.

• Replace the needle - if you can't remember when you last changed it, it's overdue
• Make sure you're using an embroidery needle, not a standard sewing needle - embroidery needles have a larger, specially shaped eye designed to protect the thread at high speeds
• Change needles every 8-10 hours of embroidery or when switching to a new fabric type

Upper tension that's too tight is a common cause of thread breaking - it puts too much stress on the thread as it forms each stitch.

• Ease the upper tension back slightly and test on scrap fabric
• Metallic, polyester and other speciality threads need lower tension than standard embroidery thread - check your machine's manual for recommended settings

Running the machine too fast puts extra stress on the thread, particularly with finer or speciality threads.

• Slow the machine down and let it run at a moderate, steady speed
• Metallic and speciality threads in particular perform much better at slower speeds - this single change often resolves breaking with these thread types

Burrs or rough spots on the needle plate or bobbin case can shred thread as it passes through, causing it to snap.

• Run your finger gently around the needle hole and feel for any rough spots
• Check the bobbin case for any signs of damage or rough edges
• Clean any lint build-up from around the bobbin area and hook assembly while you're there

Fabric that isn't hooped firmly enough can shift during embroidery, putting uneven stress on the thread and causing it to snap.

• Check the fabric feels taut in the hoop with no give or movement
• Re-hoop if necessary, making sure the fabric is secure but not stretched or distorted

Using the wrong stabiliser or not enough of it means the fabric moves more than it should during stitching, which increases stress on the thread.

• Make sure your stabiliser choice matches your fabric type and the density of the design
• If in doubt, use a slightly heavier stabiliser and see if that makes a difference
• not sure which stabiliser if right? Check out our Complete guide to embroidery stabilisers 

Before returning to your project, run the design or a test stitch on a piece of scrap fabric of the same type. Confirm the thread is running without breaking before you commit to your actual piece.