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I was wondering if you could offer any advise on to what causes needle breaks when switching to cap frames? My Toyota 9000 sews just fine on flats, as soon as switch over to cap frame and begin sewing, pop goes the needle.

Thanks, Eric.


AJST = Broken needles when doing caps can be caused, by a number of things. Here is a list of the things that I check when troubleshooting this issue.

  • In-Correct hooping = Review the correct method for hooping caps
  • Needle plate = Don’t forget to change the needle plate to the cap plate
  • Caps =
    • Are your caps structured or non-structured? There are different methods of hooping for each type of cap.
    • What brand of cap are you using? Some brands of caps are difficult to sew
  • Your design=
    • Size = most machines recommend designs that are 2 to 2.5 inches tall
    • Check the density settings on your design = if they are too dense you may have issues with needles
    • Is your design digitized for a cap? It should sew from the center out and from the bottom up.
  • Needles = you can go to a larger needle and it may help with the breaks
  • Tension = If the tension is set too tightly it may cause the needle to flex and break
  • Timing = you may need to check the timing on the machine