thread breaks

are you getting thread breaks on every needle... on a 12 needle machine have you tried needle 2 and needle 10 for example?

Have you watched the design sewout and taken note if it breaks in the same spots? This would be cause to send back to the digitizer so they can edit that section. It also could be packed with too many stitches especially if it breaks on fill sections.

It also sounds to me that the problem sounds in the digitizing. and your stitches are to close together.

I would agree with the above. Thread breaks can be controlled in the digitizing software for the most part. Small letters and packed fill are areas you need to pay close attention to. You can also slow the machine down to less than 600 SPM in really tight areas. There is a fine line between too many stitches and not enough. Find the sweet spot for your machine.

If you are getting breaks on everything you do on most or all needles, your machine may be out of alignment or the timing could be off a little. The bobbin may also be to tight. The back side of the sewing will answer that for you.

If you have several designs that sews well while others don't it is most likely in the software and the settings. Try to "Tidy Up Stitches" in your design about 0.3 - 0.9 to see if that helps.

The other thing to look for is the little wheels behind the thread tension head. If the sensor and each wheel don't line up dead center you will get FALSE thread breaks. You can bend the arm slightly to bring it into alignment. (I didn't tell you to do that, a machine tech should service it for you if you're still under warranty) I had this problem when my machine was new. You can also polish the wheels on the front to make them run smoother. This also helps with false thread breaks.