Thread nesting mostly happens due to operator error.
1)- Switch off and unplug your machine.
2)- Check if your needle is bent or dull, if it is then replace it. Plug in your machine and switch it on, do a stitch check. Your problem might end here. If it doesn’t, go to step 3.
First and foremost I recommend the use of thread net. Cover your spool with thread net while embroidering, no matter if your spool is placed horizontally or vertically on your spool holder. We all know that the embroidery thread is silky and slippery, it unravels while stored, so what is keeping it from unraveling while embroidering? Very often it slips (unravels) too fast and comes out from between the tension discs. In 80% of the cases this is what is wrong, the loose thread results in thread nesting. Sometimes the opposite happens: the thread gets tangled around the spool holder pin, it can’t go further and becomes tight then gets caught, bending and breaking the needle. Try this first, it is the easiest and more than likely the only thing you have to do for solving thread nesting problem. Only if this solution doesn’t work take the following steps:
3)-Remove the upper thread from the entire path.
4)-Clean the thread path with special attention to the tension disk.
5)-Re-thread the upper thread, making sure you follow the path correctly. All this time you must have the foot up and the needle in the highest position. You might have the problem solved at this stage, plug in and switch on the machine and check. If the problem persists, go to step 6 but make sure to have your machine switched off and unplugged every time you do adjustments.
6)- Remove the bobbin and bobbin case, clean the bobbin area and check the bobbin case for possible thread caught under the tension spring. Make sure the foot is up and the needle is in the highest position while doing this.
7)-Place the bobbin and case back, pay attention to the correct bobbin orientation. Also make sure the bobbin is the right one for your machine and is wound evenly. If all ok with the bobbin, plug in and switch on the machine. Start sewing, check for nesting. Should be ok but if the problem is not gone then you have to go to step 8.
8)- This should be used only if nothing else works. Adjust the upper tension, tighten just a slight bit at a time. After every tightening check the seam again. Keep in mind, don’t mess with the tension unless is absolutely necessary!
Is your problem solved? Leave a comment! Questions also welcome, I’ll answer ASAP.