Friends, That is all great advice and I will look at each item separately and find some application for it. But for now, I am happy to report the first suggestion was the one that stood out to me, and made the most sense since it was happening on two machines, identically. I really wanted to blame the machines, since my Tajima was running the same file without a hitch at all. The digitizing (mine and Design Shop) included DS digitized small letters, Melco Block CP, .32 inches tall @ 55% width, 4.4 density, 1100 SPM, and I changed the tie ins and outs from #1 to the #3, and rearranged the order (left to right instead of center out) and it seems to have helped, not one problem in 5 shirts. I thought that the tie-ins and -outs were part of the digitized letter/fonts, but I am glad to see I can make some corrections easily. Thanks for your immediate response and help, This list ROCKS, Dave P. David Kohler Integrity Embroidery a member of Trinity grafX 7942 Mainland Dr., Suite 102 San Antonio, TX 78250 210-798-3200 210-798-3202 fax 210-854-5702 cell =========================================================== =========================================================== The AmayaUsers Mailing List Website: http://www.amayausers.com Discussion Board: http://www.amayausers.com/boards Subscribe/Unsubscribe: http://www.amayausers.com/list ===========================================================