Do you have pe design ? I didnt get that from your post. It may be a bad digitized design and cant be reduced in density without destroying the integrity of the design .(holes , blank spaces )
To Resize and reduce the density of a design:
1.Open the design in Layout and Editing.
2.Choose the design Page property 5X7.
3.Check the Stitch Simulator and note the number of stitches.
4.Go to Edit down that column choose Numerical Setting.
5.Choose Size. A box opens now click the % button and reduse to 70%. Also Check a x in the KeepDensity box.Click OK.
6.Go to Edit again down the column choose Numerical Setting.
7.Choose Size. The box opens now click the % button and raise the % to max (keep Clicking till it stops).Now set it down by only ten numbers less.[e.g from Max of 220% down by ten will be 210%].
8. DO NOT CHECK THE X IN THE KEEP DENSITY BOX.
9.Click OK.
10.Go to the Stitch simulator and you will see that the number of stitches are greatly reduced.
I do this with a lot of designs and by trial and error you will begin to judge the % of stitches that you want to reduce.
Some designs are too dense for a T-shirt so I will do the same thing for them.
To summerize:
Reduce the size with the Density checkbox X. Then increase the size and not X the Density checkbox.
From Bev
Do you know where the design comes from that you can give a link?
By law you can not email anyone the designs.
Also most digitizers do not allow manipulation of their designs in their copyright agreement. If we knew the site that they came from we could be certain of the terms.
How many stitches are in the 5" and 6" designs?
It sounds to me like it may be a stabilizer issue.
Do you have software that you can get a picture of the design and upload it here?