Barudan Embroidery Machine Puckering or Distorted Designs Troubleshooting

1. Incorrect Hooping high likelihood

How to tell

The fabric appears loose, wrinkled, or stretched within the hoop. Designs may be misaligned or have uneven stitch density, leading to puckering around the embroidery.

Fix

1. Remove the hoop from the machine.
2. Unhoop the fabric and stabilizer.
3. Re-hoop the fabric and stabilizer, ensuring the fabric is taut like a drum skin, but not stretched. Avoid pulling the fabric excessively, especially on bias or stretchy materials.
4. Ensure the hoop screw is tightened securely to prevent fabric slippage during embroidery.
5. Verify that the hoop size is appropriate for the design. Using a hoop that is too large for a small design can lead to instability.

Parts involved: Hoops & frames →

2. Improper Stabilizer Selection or Application high likelihood

How to tell

Puckering or distortion is evident, especially on lightweight, stretchy, or delicate fabrics. The fabric may shift during embroidery, or the stitches may not lay flat.

Fix

1. Identify the fabric type and weight. Consult a stabilizer guide for recommendations.
2. For lightweight or stretchy fabrics, use a cutaway stabilizer for permanent support.
3. For stable fabrics, a tear-away stabilizer may be sufficient.
4. For delicate or water-soluble applications, use a wash-away or heat-away stabilizer.
5. Consider using a double layer of stabilizer for very dense designs or unstable fabrics.
6. Ensure the stabilizer is smooth and free of wrinkles when hooping with the fabric. If using adhesive spray, apply evenly and allow to become tacky before hooping.

Parts involved: Threads & supplies →

3. Inconsistent Thread Tension high likelihood

How to tell

Loops visible on the top or bottom of the fabric, excessive pulling of the fabric, or the bobbin thread showing through on the top side (upper tension too tight) or the upper thread showing on the bottom side (upper tension too loose). Puckering around stitches.

Fix

1. Perform a tension test stitch on a scrap piece of the same fabric and stabilizer. A balanced stitch should show approximately 1/3 bobbin thread, 1/3 upper thread, and 1/3 interlocked in the middle on the underside of the fabric.
2. Check the upper thread path for any obstructions, tangles, or incorrect threading through the tension discs, thread guides, and take-up lever. Re-thread the machine completely if unsure.
3. Adjust the upper thread tension dial in small increments (e.g., 1/4 turn) and re-test. Tighten to reduce loops on top, loosen to reduce bobbin thread showing on top.
4. Inspect the bobbin case for lint or damage. Ensure the bobbin is wound evenly and seated correctly in the bobbin case. Check the bobbin tension by holding the bobbin case by its thread; it should unwind smoothly with a slight tug, not freely fall or hold too tightly. Adjust the small screw on the bobbin case if necessary (turn clockwise to tighten, counter-clockwise to loosen) in very small increments.

Refer to the '06 Thread guide' and '03 Take up lever' sections of your Barudan parts manual for component identification related to the upper thread path. The bobbin case is part of the 'Rotary hooks & bobbin cases' assembly.

Parts involved: Thread path & tension →

4. Incompatible Needle Type or Size medium likelihood

How to tell

Fabric damage (holes, snags), skipped stitches, thread breaks, or puckering, especially on delicate, stretchy, or densely woven fabrics. The needle may struggle to penetrate the fabric cleanly.

Fix

1. Identify the fabric type and thread weight being used.
2. For general embroidery, use a sharp point (R) needle. For knits or stretchy fabrics, use a ballpoint (SES) needle to push fabric fibers aside rather than piercing them.
3. Select the correct needle size: Smaller needles (e.g., 65/9, 70/10) for lightweight fabrics and fine threads. Larger needles (e.g., 80/12, 90/14) for heavier fabrics and thicker threads.
4. Replace the needle. A dull, bent, or burred needle can cause significant fabric damage and tension issues. Always use a new, sharp needle for each project or after a few hours of stitching.
5. Ensure the needle is inserted correctly, fully seated, and facing the correct direction (scarf to the back).

Needle bar components are found in the '04A-1 Needle bar A(Z12)', '04B Needle bar B', '04C Needle bar C', and '04D Needle bar D' sections of your Barudan parts manual.

Parts involved: Needles & needle bars →

5. High Design Density or Small Lettering medium likelihood

How to tell

Excessive pulling on the fabric, especially in areas with many stitches. The fabric may appear gathered or distorted around dense design elements or small text.

Fix

1. If possible, edit the design software to reduce stitch density in overly dense areas, particularly for lightweight or stretchy fabrics. Consult your digitizer.
2. For small lettering, ensure proper underlay is used, but avoid excessive density. Sometimes, reducing the stitch count can improve results.
3. If design modification is not an option, use a stronger or double layer of stabilizer to provide maximum support to the fabric.

Parts involved: Threads & supplies →

6. Machine Speed Too Fast low likelihood

How to tell

Fabric shifting or movement during stitching, leading to distorted designs. This is more apparent with intricate designs, delicate fabrics, or when other issues (like hooping) are present.

Fix

1. Reduce the machine's operating speed, especially for intricate designs, delicate fabrics, or when experiencing distortion.
2. Adjust the speed setting on the control panel. Start at a lower speed (e.g., 500-600 SPM) and gradually increase if the quality remains good. Refer to your Barudan machine's operation manual for specific speed adjustment procedures.

Parts involved: Control panels & displays →