Ann The Gran Community

I've had my Brother Innov-is 900D since Christmas and have tried several projects.  I was putting a design on an apron yesterday and the top thread kept nesting below the plate.  The top thread had also broken 3 times as well.  I wonder if the apron which I got a 3-pack at Hobby Lobby has imperfections in the material that made this happen or if I'm doing something wrong.  I had cut-away stablizer and a 80/14 sharp needle. 

I'm learning by trial and error, but cannot find anything in my manual about this particular problem.  I'm sure all of you experts out there can steer me in the right direction.

Refer to the maintenance section of the instruction manual for cleaning the bobbin case and surrounding area.

Re-thread the machine, using a new needle, and then try the design on a different fabric. 

It could very well be the duck/canvas is the issue, however, I have not had an issue with aprons, totes or carpenter aprons made of this product.  A larger needle may work better as this is a coarse, tightly woven fabric.

Pattiann is right on!  I would do some more things.

You do not mention doing a 'discovery' sew.  That is when you use the same or similar fabric and test the pattern.  That will help a lot in determining your specific issue. 

I would do your discovery with a lighter stabilizer because having canvas, which can be very heavy, and a heavy stabilizer could be causing some of the issue.  Stabilizers are a balancing act.  Sometimes they need to be adjusted.  Canvas needs a lighter stabilizer, IMHO.

Additionally, you may want to try doing a 'Tension Test.'  These are tests, relative to your machine, that will show you if your thread is too loose on top.  That can also cause nesting. 

I don't recommend learning 'by trial and error' because it can be a big waste of time, money and materials, not to mention the frustration and disappointment.  You may want to look over the instructions here for newbies (we LOVE you!!).   While it is written for the Brother PE700, it is very helpful for other machines and is written for beginners. 

Lastly, if you got that thread from your dealership with your machine, I just want you to know that 'aged' thread can be dry and brittle.  They may have wanted to get rid of some items that have been sitting around for a while.  Try a couple of drops of Sew Ease which is silicone based and let it dry on the thread.  That only takes a minute or two to dry and will add life back to your thread. 

There are many reasons for each of your concerns.  My opinions are based on my adventures and frustrations.

Pat, The Avid Embroiderer

Thank you for the advice.  I will try all of the items you suggested.

Pattiann & pat71896, I do test patterns or "discovery" sews on big squares of felt. Everything seems to work fine, but I'll take your advice and test on similar fabric to get the right settings.  I will try to Sew Ease and I read about Sewer's Aid for the needle as well.  I'm just about 50 and haven't sewn for 20+ years....kids, dogs, job, etc., but now want to get back into the swing of things to teach my 5 year old granddaughter, Allison, how to sew.  I do alot of cross-stitch and plastic canvas projects and she is learning those as well.  She has about 10 designs picked out for me to put on her clothes.  I still get puckering on her t-shirts so I'm trying to master that as well, but her denim jumper came out great.  I learned sewing in 4-H and having you guys all here to answer questions is like having my mom back with me.  I really appreciate your patience and expert advice.  Sewing machines have come along way in 20 years.  Thanks again, Amaress

I also began sewing when I joined 4-H.

I have never used Sew Ease, but have use Sewer's Aid.  Through April 24, Sewer's Aid is 1/2 price at JoAnn's Dritz Notions Wall sale.

I am not quite old enough to be your mom.  But I think Pat may be!     

Gotta go now.  I have a lot to do before bedtime!

Pattiann must have peeked at my profile, it says that I am 2001 years old. . . .  That makes me older than dirt!

And, she is right, that is Sewer's Aid, not Sew Ease. 

Back to the nesting issue, it is very important that you use the same material (or as close as possible) to do your discovery.  Fabrics vary a great deal, duh.    The weight (density) of your design matters a great deal, the stabilizer - - - well, you get the photo.

Pat, The Avid Embroiderer

All the suggestions  you have been given are great! If all those fail, you might have a burr on  your plate. I have had that to happen to me before. I got a new plate and did not have any more trouble!

I read in a few other places about burrs.  I did buy some 400 grit sandpaper as it mentioned, but I'm not exactly sure where all to sand to get any burrs taht I may have.  Do you mean just to top, flat metal surface under the presser foot?

I believe you use strips of crocus or emery cloth.  Be sure to remove the needle plate to do this.  You do not want any grit to fall unto the bobbin area.

Refer to the maintenance section of your machine's instruction manual for how to remove the needle plate and for general cleaning of the bobbin area.

I cleaned my machine, sanded the needle plate and also the disk that holds the top spool in place...it also had rough edges so I sanded those as well.  I am happy to say that I embroidered all day Sunday with no problems..thanks for all the help.