Don't stress.. Our gifted and very talented cuties will have the solution to your problem. Have you used this font before? I find sometimes with the free ones it can be the way it was digitized, maybe a change in style will do the trick.. marian

Sometimes when you reduce the design too much, then this happens. It is then too dense. Try making the font bigger. Hope it helps.

Just recently, there were a couple of articles posted with tips/instructions for dealing with small fonts. Hopefully another cutie will come along who remembers which website has them posted. In the meanwhile I will try to find them again for you. They did mention the density issues, and suggested to remove underlay stitches when making small letters.

Was this the original size of the font or did you reduce it to 1/2 inch? If you did reduce it, what was the original size of the font you purchased?

I have no clue why this happens. Seems that I try everything, and nothing fixes the problem. Often, like it looks in your photo, I get loops in the exact same places when I stitch it a second time. Sometimes I just don't have time to figure it out. When that happens and I really want the design, I sit right by my machine and set the speed pretty slow. When I see a loop, I back up a few stitches and stitch over it. That flattens the loop so you can't see it.

Sometimes, if I miss seeing a loop, I try to pull the loop to the backside. I put a pin through the top side where the loop is. Then I gently pull on the threads on the backside, keeping an eye on the front, until I find which one is the loop and just pull that thread to the back.

If it is a really dense design, I cut the loop away and put a small dot of Fray Check on the back side where I cut away the loop on top to make sure it doesn't unravel. If you use too much Fray Check, it can bleed throught to the top and make a mark. So I dip a pin in the bottle to get a drop, sometimes twice, and use that instead of squeezing the bottle.

I've taken my machine to the shop, replaced the tension module, serviced the machine...and still get loops.

Try rethreading both bobbin and machine. Try a way to set thread behind and raised at machine. Clean tension on machine by folding fabric in half, work folded edge down thru tension area. Doesn't hurt to clean bobbins.

SQ

The density is too high.....you need to reduce it. When I digitize small fonts I reduce the density from my default setting by half as much. When the letters are so small, the stitches are right on top of each other. Try reducing from the default.

You might consider using 60wt yarn instead of the normal 40wt. It is much thinner and gives excellent results for small letters.
If can't get that or don't have it reduce the density. That may however make the curves a bit jagged.

Hmmm, I saw below that you did not reduce the size of the font, it came in the 1/2 inch size...I would contact the site where you purchased it...but before you do that, I would try stitching out the same wording in one of the other sizes you purchased to see if they have the same problem, or it is only with the 1/2" font...also I would try out some of the other letters in the 1/2 inch size just to see if they are also affected...have you stitched this more than once and do the loops always occur in the same places...it looks like they might looking at your sample...all of the "1" look like they have the same problem...it might be a digitizing problem...

I agree with Mops, try a finer thread, use bobbin weight if possible. Sulky has a new line called Poly Lite for just this purpose and works great. Hugs. Nan W

thank you so much for all the tips and advice.

I haven't read all the posts but I have learn not all digitizers are the same!

you did not mention what wt. thread you have used. With small fonts you need 60 wt threads. Try www.threadart.com or www.annabove.com. I got mine, a set of 24 colors for a really nice price.

Looks like you are using Black thread try a sample with another colour. Black thread is renown for having problems something to do with the dying process it makes some threads hairy. I changed to a Ralston for black no more problems.