Let’s be honest—sometimes machine embroidery doesn’t go as planned. Maybe your thread snapped (again), your design looks wonky, or the fabric puckered like a raisin. Don’t worry! Every embroiderer (even the pros) faces a few hiccups. Here’s your go-to guide for troubleshooting common commercial embroidery fails—so you can fix mistakes and get back to stitching awesome stuff.

1. Thread Breaks (a.k.a. The Dreaded Snap)

Why it happens:

• Wrong needle size or type

• Old or low-quality thread

• Tension is too tight

How to fix:

• Switch to a new, quality thread spool

• Double-check your needle and replace if needed

• Adjust upper thread tension (loosen it a bit)

2. Puckered or Distorted Fabric

Why it happens:

• Fabric not hooped tightly enough

• No stabilizer or the wrong kind

• Design too dense for the fabric

How to fix:

• Re-hoop your fabric—aim for “drum tight”

• Use the correct stabilizer (tear-away for stable fabrics, cut-away for stretchy ones)

• Choose or edit designs with lighter stitch density for delicate fabrics

3. Skipped Stitches

Why it happens:

• Dull or bent needle

• Incorrect needle for the fabric

• Machine timing is off (rare, but it happens)

How to fix:

• Replace the needle with a new, sharp one

• Make sure you’re using the right needle for your fabric type

• If the problem persists, consult your machine’s manual or a technician

4. Misaligned Designs

Why it happens:

• Fabric shifted in the hoop

• Hoop too large for the design

• Machine not calibrated

How to fix:

• Always double-check hoop tightness before starting

• Use the smallest hoop that fits your design

• Run a test stitch and recalibrate your machine if needed

5. Bird’s Nesting (Thread Bunching Under Fabric)

Why it happens:

• Improper threading of the machine

• Bobbin not inserted correctly

• Tension issues

How to fix:

• Rethread your machine, top and bottom

• Remove and re-insert the bobbin

• Adjust tension as needed

6. Design Looks “Off” or Messy

Why it happens:

• Poor digitizing (file not set up well for machine embroidery)

• Wrong thread colors or types

• Skipped test stitch

How to fix:

• Use professionally digitized files, or ask for help refining your design

• Double-check your thread choices

• Always, always test on scrap fabric first

Final Thoughts

Mistakes happen! The key is to stay calm, troubleshoot step by step, and don’t be afraid to ask for help (or Google it—we’ve all been there). With each fix, you’ll get more confident and your embroidery will look better and better. And remember, even the wonkiest project can be a learning experience—or a “rustic” original!

If you’re stuck on a problem, RM Custom Screen Printing is always here to help you troubleshoot and get your project back on track.