Without looking at the design, I couldn't diagnose the problem, but I the key thing you mentioned is both machines had trouble on the design - which means it's the design itself. Almost every design needs to be adjusted depending on the item it's been sewing on. In this case, you went from a polo that probably was about 5oz. to something 14oz. thick. There's a lot to adjust between the two. I'm going to guess some of our digitizing experts will be along shortly to suggest tweaks to get you running. I don't think the solvy is necessary and am guessing with a two layers are ok, but you could easily get away with one given the fabric thickness. You running ballpoints or sharps on that and what size? What happens when you run with Actifeed instead of manual Material Thickness? From: amayausers-bounce@xxxxxxxxxxxxx [mailto:amayausers-bounce@xxxxxxxxxxxxx] On Behalf Of JerryNiez@xxxxxxx Sent: Tuesday, September 11, 2007 10:21 PM To: AMAYAUSERS@xxxxxxxxxxxxx Subject: [amayausers.com] Thread fraying and breaking problem Can anyone offer an explanation of why I am breaking thread? I have a design with 14,500 stitches in a 2.7 diameter design. I have run the design on pique shirts without many problems. I also ran the design on a 3 season jacket with a fleece lining. I had an occasional thread break but completed 36 garments. I then tried running on a 14 oz fleece pull over and had nothing but trouble. I have 2 Amayas and both experienced the same thread breaking problem. I tried material thickness from 8 to 12, changed needles several times and tried speeds from 700 to 1,100. I could only stitch 50-75 stitches before the thread frayed and then broke. The fleece was covered with solvy and backed with 2 layers of stabilizer. What do you think is the problem and how do I solve the fraying thread problem? I have 15 pullovers to complete. Jerry Artistic Embroidery & More Traverse City, MI _____ See what's new at AOL.com <http://www.aol.com?NCID=AOLCMP00300000001170> and Make AOL Your <http://www.aol.com/mksplash.adp?NCID=AOLCMP00300000001169> Homepage.