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Likely tension too high or thread is snagging somewhere.
With machine threaded, test top thread feed and tension as follows.
Needle up, presser foot up, tension set to 4. Make a long slow steady pull of thread. The thread should advance smoothly and freely through needle eye. Any snagging or sudden change in tension is suspect. Make a couple more pulls to make sure thread doesn't snag while unwinding from spool. Note this is no tension as presser foot is up which opens tension plates.
Lower foot and make a couple more slow steady pulls. Thread should advance smoothly through the eye of needle. Note the change in tension with foot down.
If feed/tension tests ok, then could be problem with bobbin area, but I'd expect more symptoms, such as thread balling underneath when top thread breaks.
Could be a multitude of things. Use only good quality thread--no old or bargain bin threads. Try a different brand of thread--some machines prefer certain brands over others. The needle and thread should be compatible--ie needle eye shouldn't be too small for thread weight. Burr catching the thread and breaking it. Upper tension too tight.
Remove the upper thread, RAISE the presser foot and rethread from the beginning. Verify the thread is not looped incorrectly in the thread path, like around a thread guide or around the spool pin. Is the thread snagging on the thread spool itself? Do you see the thread tightening as you sew and eventually it breaks? This indicates it is catching somewhere between the needle and spool. Is it shredding at the needle eye? This indicates the needle eye is not suitable for the thread being used.
Watch where the thread is breaking. This will sometimes give you a clue where the problem exists.
If the top thread sews a few inches and then breaks, something is catching the top thread and holding it until it breaks. Usually, this will happen when using the old style thread cones with the slit in the edge to keep the thread from raveling off the spool. To prevent the thread from hanging up, turn the thread spool over so the slit is at the top instead of the bottom. Sometimes top thread breaks will happen if the thread becomes looped around the thread spool pin.
Remove the thread, ALWAYS RAISE the presser foot and then rethread the upper thread. Verify that the thread path is correct and that the thread has not looped around a guide.
If the thread is fraying at the needle eye, the needle/thread are not compatible. Also, the tension may be too high.
Check that the upper tension disk is clean--no gunk buildup or thread pieces stuck.
If the thread is actually breaking when it penetrates the needle plate hole, there may be a burr or nick somewhere below that is catching the upper thread. You can wrap your finger with a piece of fine fabric, like an old pair of hosier, fine knit fabric, etc. and running your finger around in the bobbin area, under the needle plate. If you get snags, then you have a burr or nick. If it is small, you can sometimes smooth it with a fine emery board. If it is a large burr, you may need to purchase a replacement part.
Make sure the thread coming off the spool is not wrapping around the spool spindle. Install a brand new needle. Remove ALL the thread from the machine. Clean bobbin area of any dust, lint, threads. Set upper tension to the midpoint. RAISE the presser foot and then totally re-thread the machine from beginning to end verifying the sequence is correct. Test.
You do not say which machine you have. As for a straight stitch, make sure the needle is central and not in zig zag mode.
The thread can break for several reasons, such as. Incorrect tension.
:Wrong thread for the material.
: Thread in bobbin different from the top thread.
:Old thread.
: Not threaded correctly.
: Needle not inserted correctly, or incorrect needle.or the thread could be wound around the spool holder pin,
Try removing the spool and turn it around.
Hope this helps.
Upper thread breaks
1.the needle may be bent or damaged--try rolling the needle on a flat surface to see if it's bent or not
Or the needle could be in backwards
Correct needle insertion
Correct needle insertion is mandatory for proper use of sewing machine.
Raise the needle bar to the highest point, then loosen the clamp screw to remove the old needle, place the new needle in the clamp with the flat side to the back of the machine or if using a round needle--the groove in the needle should face away from the shaft.
Push the needle all the way up to the stop or as far as it will go, then tighten the needle clamp screw
2.upper tension may be to tight--try 3 to 5
3.thread may be hanging up in bobbin case--check area for loose threads or lint
???
Lower thread breaks
The most probable cause of lower thread breaking is improperly wound bobbin
1.always start with a empty bobbin
Never wind one color over the other
2.choose thread that is identical in color & type as the one to be used for upper threading
3.wind the bobbin evenly across & in layers
4.don't wind the bobbin so full that it would be tight & hard to insert into bobbin case
5.bent bobbin--replace
6.lint built up in the bobbin case--frequent cleanings will eliminate this problem, the more often you use the sewing machine the more often it needs to be cleaned
7.thread catching on the bobbin spring or latch on bobbin case, check to see that the bobbin is inserted completely & correctly, & that you are using the right kind of bobbin
for the top & bobbin thread keep thread tails of 3 to 6 inches long pulled behind the needle before you start sewing
yes,sometimes the thread will get caught on the spool, you might think about getting a extra holder that sets behind the machine to hold those spool's that the thread get caught on, that's what I did.
Not sure if you noticed but if you thread a machine with the pressure foot down it will not thread correctly. There are two little things that sorta looks like symbols for the tension on most machines. (learned this when my viking 600e kept breaking thread and I put it in shop) If you thread the machine with the pressure foot down it closes the symbol things and the thread will break as you described. If you have completed that correctly check the spool of thread. You may have a burr on the thread spool that is catching the thread that too has happened to me.
here are something you might check
upper thread breaks
1.top tension to tight
2.thread to thick or to fine for needle
3.needle not inserted correctly
4.thread caught on something-spool pin, tension area
5.needle damaged
6.needle thread is not threaded properly
Needle breaks
wrong size needle for fabric
wrong foot is attached
needle clamp screw is loose
also check for lint & pieces of broke needle under the needle plate
also the bobbin case area -take the bobbin & case out & check for pieces of broke needle
here is a tip about needle & thread
Cut 6-8 inch piece of thread of the spool you are going to use for your project
Take the needle you are going to use for the project
& insert the thread thru the eye of the needle
& lift one end of the thread to a 45 degree angle
& if the needle is the right size for the thread it will slide down the thread
But if the needle hangs on the thread you need one size larger needle for the thread
If the thread is hanging up at the spool - this could be the way it was manufactured, a nick in the spool end or the thread is unwinding too fast, puddling and wrapping around the spool pin.
Keep the bobbin case and surrounding area clean and free of thread tangles and snips. Thread tangles in this area can cause the machine to stop.
When the presser foot is down on any sewing machine, the tension closes and you cannot manually pull the thread through.
Sulky and C & C black tends to fray more than other brands of thread.
If the problem continues, the machine will need to be serviced by a professional.
* Rethread your machine An incorrectly threaded machine can cause thread to break.
* Decrease the tension on your machine The tension may be too tight for your thread.
* Reposition the spool of thread on the spindle You know that little nick in the edge of a spool that’s used to hold the loose end of the thread? Your thread may be catching on this nick as you sew. Place your spool so that this nick rests against the bottom of the spindle.
* Reinsert your needle Make sure it goes all the way into the holder and that it’s positioned correctly, usually with the flat side away from the bobbin, but consult your machine’s manual to be sure.
* Change your needle Your needle may be bent or dull. The eye of your needle may have a nick in it that’s cutting the thread as you sew. Or your needle may be too small for the thread you’re using, in which case, change to a larger needle. And make sure your needle is appropriate for the weight and type of your fabric.
* Change your thread Your thread may be weak. Or your thread may be fuzzy and irregular, causing it to catch in the eye of your needle as you sew. Cheap thread tends to be weak and fuzzy, so make sure to use a quality, brand name thread. And if you’ve been sewing with an older cotton thread, which can dry out and become brittle with age, try a newer thread.
* Check your presser foot for damage to the needle hole A burr in your presser foot’s needle hole may be cutting your thread. Gently smooth any rough spot you find with an emery cloth.
* There may be a burr in one of your thread guides, in which case, you may need to have your machine professionally serviced to have the part replaced.
If it's Your lower thread breaking:
* Reinsert your bobbin Your bobbin may not be seated properly in its case.
* Rethread your bobbin Your bobbin may be threaded incorrectly or the thread may be tangled.
* Remove some of the thread from your bobbin If your bobbin is very full (if it’s hard to insert into the case, it’s too full), this may be keeping your bobbin from turning smoothly.
* Rewind your bobbin thread If your bobbin thread is wound unevenly, this may be keeping your bobbin from turning smoothly.
* Try a new bobbin There could be a nick along the edge of your bobbin spool that’s catching your thread as you sew.
* Clean the lint from your bobbin case Lint in your bobbin case could be keeping your bobbin from working properly.
* Check the needle hole in your throat plate for rough spots A burr in the needle hole of your throat plate, usually caused by the needle hitting the throat plate, could be cutting your thread. Gently smooth any rough spot you find with an emery cloth.
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