Thanks to Herb... I tried adjusting settings that you mentioned... and it sewed out, but the thread did't fill quite so well with a higher number density. So, I went to a true type font, re-did the lettering and set the properties along the lines of what both of us were thinking and you know what... I can do 8-10 shirts without a break now.... and it covered better at the 4.8 density. So I am happy. Thanks for kicking my brain into gear. - - - - John Yaglenski Chairman & CEO, Levelbest Communications I: http://www.levelbest.com P: 888.229.1779 / 301.591.2481 Levelbest Network Sites Include: intercot.com / webdisney.com / intercotwest.com urbanamaryland.com / mousehut.com / udflyers.com levelbestembroidery.com