Most likely, it has to do with incompatibility of the needle, thread, and fabric. The force of the needle penetrating the fabric multiple times is actually causing the thread to (wear &) fray and eventually break. There are needles with larger grooves that tend to protect the thread during stitching. Some may recommend a Top Stitch Needle (
Home Machine Needles Superior Threads Why Topstitch? The Topstitch needle is the most common needle type used and recommended by professionals and educators. We recommend the Topstitch for piecing, quilting, embroidery, appliqu?, and construction. These needles are available in four sizes to accommodate all thread types, including metallic threads. The Topstitch needle has a larger eye and deeper groove. It is often referred as the MAGIC NEEDLE. It really does make a difference in your sewing experience.)
Why Use Topstitching Needle
Also, if the thread is a tight fit through the needle eye, it will also tear the thread. Make sure that the thread will slip easily through the eye. Go to a larger needle, instead of 90, try a 100.
Be sure to use a brand-new needle.
All About Needles
The Parts of Sewing Machine Needle
You may also consider changing the type of thread you are using. Go with a stronger thread, ie polyester, rather than cotton. Cotton will shred and break easier.
You will probably need to re-adjust the thread tension. If it is too tight, it will also break the thread. If you are using a heavier weight of thread, you will need to adjust both the upper and bobbin tension to accommodate the heavier thread.
Bobbin Tension How and Why Tension is Adjusted
If you sewing fabric that is sticky, ie vinyl, oilcloth, you should try to use a roller presser foot, a teflon presser foot, or a walking foot to help the fabric move with the feed dogs.
Sewing Heavy Fabric with NON Heavy Duty Sewing Machine SEWING IN GENERAL
Tips
Sewing through many thick layers of fabric Sactin
http://www.kollabora.com/q-a/sewing-denim-and-thick-fabric
14 Fantastic Sewing Tricks and Tips Making the World Cuter
How to Sew Upholstery DoItYourself com
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