Why Does My Upper Thread Keep Breaking While I Sew? 10 Common Reason

Sewing is a rewarding hobby, but it can be frustrating when your upper thread keeps breaking while you work. Whether you are a beginner or an experienced seamstress, breaking the upper thread can be frustrating and can interrupt your sewing flow. But, there are several reasons why this might be happening and some simple solutions to fix it. In this article, we will explore the most common causes of broken upper threads and give you tips on how to prevent them from happening in the future. So, if you’re tired of dealing with broken threads, keep reading to learn more!

Here are the top 10 reasons why the upper thread breaks, and what to do about each one.

1. Incorrect thread tension

Incorrect thread tension can cause the upper thread to break while sewing because if the tension is too loose, the thread will not be pulled tightly enough through the fabric, causing it to break or knot. On the other hand, if the tension is too tight, it can put too much stress on the thread, causing it to snap. Maintaining the correct tension is crucial for smooth, consistent stitching and to prevent the upper thread from breaking.

2. Dull needle

A dull needle can cause the upper thread to break while sewing because it can cause the thread to fray or get snagged on the fabric, leading to breakage. Additionally, a dull needle can create jagged holes in the fabric, which can also cause the thread to break.

To solve this issue, the solution is to replace the needle with a new, sharp one. Regular replacement of the needle is important for maintaining the quality of your sewing, as a dull needle can not only cause thread breakage but also affect the overall appearance of your stitching. It is recommended to change the needle after 8-10 hours of sewing or after completing a project.

3. Old or poor-quality thread

Using old or low-quality thread is one of the common causes.

To resolve the issue, here are some solutions:

• Replace the thread with a fresh and high-quality spool.
• Check the tension settings on the sewing machine and adjust them if needed. If the tension is too tight, the thread can break; if the tension is too loose, the stitch won’t be secure.
• Clean and oil the sewing machine regularly to ensure smooth operation.
• Change the needle frequently. Dull or bent needles can cause thread breakage.
• Make sure the thread is properly threaded through the machine, including all tension disks, the take-up lever, and the needle eye.

By following these steps, you should be able to reduce the frequency of upper thread breakage while sewing.

4. Incorrect needle size

Incorrect needle size can cause the upper thread to break while sewing due to improper tension balance between the needle and thread. The solution is to use the correct needle size for the type of fabric and thread you are using. A needle that is too small will not provide enough space for the thread to move freely, causing it to break. A needle that is too large can damage the fabric and cause the thread to break as well. So, it is important to refer to the manufacturer’s recommendations or a reference chart to choose the appropriate needle size. Additionally, making sure your machine is properly threaded and the thread tension is set correctly can also help to prevent thread breakage.

5. Poor thread path

Poor thread path can cause the upper thread to break while sewing for several reasons:

• Incorrect thread tension: If the tension is too tight or too loose, it can cause the thread to break.
• Poorly threaded machine: If the machine is not threaded correctly, the thread can become tangled and break.
• Damaged needle: A bent, dull, or incorrect size needle can cause the thread to break.

To solve this issue, you can follow these steps:

• Check and adjust the tension: Refer to your sewing machine manual for the recommended tension settings and adjust accordingly.
• Re-thread the machine: Make sure the thread is threaded correctly and smoothly through all the guides and the needle.
• Replace the needle: Use a sharp, correct-size needle for the fabric and thread you are using.
• Slow down your sewing speed: Sewing too quickly can also cause the thread to break, especially with thin or lightweight fabrics.

By following these steps, you can minimize the chances of breaking the upper thread while sewing.

6. Thread caught in machine parts

Thread caught in machine parts is another common reason for upper thread breaking while sewing. This can occur if the thread becomes tangled or snagged in the mechanism of the sewing machine, causing it to break.

To solve this issue, you can follow these steps:

• Clean the machine: Regularly clean the machine, especially around the thread path, to remove any lint or debris that could cause the thread to catch.
• Check for thread nicks: Check the needle and other parts of the machine for any nicks or burrs that could cause the thread to catch. If found, replace or repair the part.
• Use a thread guide: Some sewing machines come with a built-in thread guide to help keep the thread running smoothly. If your machine doesn’t have one, consider purchasing one.
• Change the needle: A dull or damaged needle can cause the thread to break, especially if it is caught in the fabric or machine parts. Make sure to regularly change the needle to keep it sharp.

By following these steps, you can reduce the chances of the thread getting caught in the machine and breaking. Additionally, make sure to always use a high-quality thread and follow the manufacturer’s recommendations for threading and using your sewing machine.

7. Fabric snags

Snags in the fabric can cause the upper thread to break while sewing because the needle may get caught on a snag and pull it through the fabric. This can cause the thread to break or become tangled.

To solve this problem, you can follow these steps:

• Check the fabric for snags before starting to sew. This can be done by running your hands over the fabric to feel for any rough spots.
• Use a sharp needle that is appropriate for the type of fabric you are using. Dull needles can easily get caught on snags, causing the thread to break.
• Adjust the tension on your sewing machine. If the tension is too loose, the thread may loop on the underside of the fabric, causing the upper thread to break.
• Slow down your sewing speed. This will give the needle more time to pass through the fabric and reduce the chance of snagging.
• Use a walking foot on your sewing machine. A walking foot is a presser foot that moves along with the fabric, helping to prevent snags and tangles.

By following these steps, you can reduce the likelihood of snags causing your upper thread to break while sewing.

8. Dirty machine

A dirty sewing machine can cause the upper thread to break while sewing because lint and debris can build up in the machine, causing the moving parts to grind against each other and create friction. This can cause the needle to bend or break, or the thread to become tangled or snap.

To solve this problem, you can follow these steps:

• Clean the machine regularly. Use a brush or air duster to remove lint and debris from the machine and its surrounding area.
• Oil the machine as needed. Consult your machine’s manual for the recommended type of oil and frequency of oiling.
• Check the needle. If it’s bent or dull, replace it with a new one.
• Check the thread path. Make sure the thread is passing through all the guides and tension discs smoothly.
• Check the spool cap and thread spool. Make sure they are properly loaded and not causing any tangles.

By keeping your sewing machine clean and properly maintained, you can reduce the likelihood of upper thread breakage due to dirty machine conditions.

9. Incorrect thread type

Using the incorrect type of thread for the fabric or project can cause the upper thread to break while sewing. Different types of fabrics and projects have different requirements for thread type, weight, and tension.

 To solve this problem, you can follow these steps:

• Choose the right type of thread. Consider the type of fabric, the type of stitch, and the end use of the project when selecting a thread.
• Use the correct weight of the thread. Heavier weight threads are better for thicker fabrics, while lighter weight threads are better for lighter fabrics.
• Check the thread tension. Make sure it’s properly adjusted for the type of thread and fabric being used. The tension should be tight enough to prevent looping, but not so tight that it causes the thread to break.
• Check for knotting or tangling. If the thread is knotting or tangling, stop the machine and carefully remove the knots or tangles before continuing.

By using the correct type of thread and ensuring that the thread tension is properly adjusted, you can reduce the likelihood of upper thread breakage while sewing.

10. Operator error

Operator error can be a reason for upper thread breakage while sewing. Some common operator errors include incorrect threading of the machine, incorrect needle insertion, improper thread tension, and pulling or pushing the fabric too hard while sewing.

To solve this problem, you can follow these steps:

• Read the sewing machine manual and familiarize yourself with the machine’s settings and controls.
• Thread the machine correctly. Make sure the thread is passing through all the guides and tension discs in the correct order.
• Insert the needle correctly. Make sure it’s inserted all the way up to the needle stopper and tightened securely.
• Adjust the thread tension. The tension should be tight enough to prevent looping, but not so tight that it causes the thread to break.
• Sew slowly and gently. Don’t pull or push the fabric too hard while sewing. Let the machine feed the fabric through at its own pace.

By following these steps and avoiding common operator errors, you can reduce the likelihood of upper thread breakage while sewing.

If you’re having problems with your bobbin thread breaking, head over to this article: Why Is My Bobbin Not Winding Evenly 15 Causes?