The only time this has happened was when I missed the mark with the stabilizer and did not fully cover the area to be embroidered--also failed to check what the back looked like after hooping. The stitches were not supported by any stabilizer and a small hole developed at that spot. I have since learned not to skimp on the stabilizer.
P.S. Always use a ball point needle on stretchy fabrics.
First thing I thought was maybe an all-purpose needle instead of a ballpoint needle, and I see I was not the only one. I, too, would suggest cloud cover on the back secure it and make it nice to the skin at the same time.
A cloud cover would not fix the hole as the leave-in stabilizer is still there. I need to stick the fabric back to the stabilize. Maybe I'll just do a zigzag stitch overr it to hold it down.
I always use a ball point needle for tees. I would iron on a backing like cloud. Makes the back of the design not scratchy against the skin. I think it will also help your design to stay in place.
I don't think I actually have ball point embroidery needles. I'll get some and try them out.
What needle did you use? I believe knits should be a ball point needle.
http://www.thorntonco.com/choose-...
Check this we site for needle for which fabric.
SQ