I am having a thread fraying problem that I have been unable to solve. I am sewing a completely re-digitized design with small letters and an outline graphic in satin stitch. The letters appear to be Micro Block caps and lowercase at .22. He digitized the letters too. My digitizer is an old hand with an excellent track record. I am sewing 5.6 oz jersey. I started with 2 oz cutaway and no solvy w/ a 80/12 BP. I had some better luck with doubling the backing but that didn't completely fix the problem. I changed to a 70/10 BP. I am using ARC 40 poly. I checked the needle to make sure it was not in backwards. I cleaned under the sew plate and made sure the oiling service was current. I don't always get a trim even though the knife actuates. There appear to be no spurs on the trimming knife. I changed the materiel thickness to 3, then 4, 5 and even 6. I get looping at 6 and thread breaks at 4 and fraying no matter where I set it. I ran the design through design filter with default 1.5 and low then went to medium and finally high. I sent the design back to the digitizer and he added some trims but said he couldn't find any problem areas in the digitizing. I tried sewing a test with block and the recommended settings. I tried several other alphabets and sizes all within the recommended parameters. I still get the fraying and goobers. This is a 2003 machine with only about 100 hours sewing time. Anyone have any ideas? Jack Fuller jack@xxxxxxxx