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[klackey28]

I just started seeing today and this has happened a few times. What caused it and how do I prevent it? Thanks

[sandmanred]

Usually some combination of needle too small/thread too large/workpiece too thick or hard.

[WILD BILL]

I will add that happened to me when I had my needle installed backwards.

[JimmieJoe]

Burr in the thread path does it for me. Any needle strikes or broken needles before it started happening. Could also be a damaged needle.
Does it continue with a new needle.

[BigRig]

Thread quality is changing. My new orders of thread of the same brands are chaffing and fraying too.