When I embroider on heavy weight fabric or stretchy fabric the thread breaks. I have tried adjusting the tension up and down, making all sorts of adjustments with stablizers, checked the needle several times, tried different needles. I have noticed that it does make thrashing sounds just before it shreads the thread and breaks. I have also noticed that it normally breaks within the first 50 stiches or when the direction of the design changes.
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The tension(s) may be too tight and could be threaded incorrectly. Start out with a brand new needle. Be sure to RAISE the presser foot when threading the upper thread. Consult the owner's manual to be sure it is threaded in the proper order. Test your stitch on a straight stitch and adjust it so both threads meet in the middle of the fabric. This setting works for straight stitch. However, usually the upper thread tension is loosened a bit for embroidery so the bottom thread will not show on the top of the fabric. Test it on some small embroidery patterns first until it's where you want it.
have you tried changing the needle rethread the machine top & bobbin when embroidering make sure it good quality thread clean under the needle plate & in the bobbin area for loose threads & lint make sure the thread your using it not knotty make sure the tension is set for the thread & needle & fabric your using make sure the thread has not come off the thread take up lever
you might try youtube for video's on embroidery The needle thread breaks
1. the needle thread is not threaded properly
2. The needle thread tension is to tight
3. The needle is bent or blunt
4. The needle is incorrectly inserted
5. The needle thread & the bobbin thread are not set under the presser foot when starting to sew
6. the threads were not drawn to the rear after sewing
7. The thread is either to heavy or to fine for the needle
With the embroidering, some of the bobbin thread is SUPPOSED to show on the top of your embroidery-the machine isn't doing anything incorrectly. You'll need to thread your bobbin with the same thread as you are using with the top. I had the same "problem" when I first got the machine and took it to a wonderful local technician whose helped me with a lot of things who informed me that this is perfectly normal on embroidery machines.
Your tension is way too loose on top or too tight on the bobbin. Try adjusting the top tension one number at a time until you get it right. (Only adjust the bobbin tension as a last resort). Also you could have different thickness of thread in the bobbin than on the top or are sewing a very heavy fabric. Try adjusting the tension with same thread in both bobbin and top and use a normal weight fabric until you find the right tension to get you back to a normal stitch before going to a heavier fabric or thread.
Be sure when you are threading the top thread that you ALWAYS RAISE the presser foot. This releases the tension disk and allows the thread to seat properly.
Have you gone back and re-tested on your test fabric? Does it work okay on the test fabric? If so, then there's a suspicion that it has something to do with the fabric, needle & thread of your project. Is your project fabric very dense, heavy... Are you using a stabilizer? A hoop--is it taut, not stretched? Make sure the fabric is not trampolining. Could be an incompatibility. The needle & thread may be having difficulty piercing the fabric. Try a different weight needle, perhaps a microtex or embroidery needle.
If the thread will not run through the tension mech on 0 then it is probably stuck on a tight setting. It can be a bit complicated but the tension mech can be stripped/cleaned/free'd up. Another possible cause is the path of the thread from the spool to the needle any deviation from the correct path increases the tension at the needle. If you do not know the history of the machine I would suggest a thorough clean and service.