Thread Fraying Occurring On One Needle:

• The needle is not positioned correctly, ie. backward or slanted. The eye of the needle needs to be facing forward.

• Burrs in the thread path or in the eye of the needle, or maybe a burr in the embroidery foot.

• The presser foot is not centered and the needle is too close to the foot.

• Thread is old or damaged; test that thread on another needle.

• Thread weight is not in accordance with the needle size.

Thread Fraying Occurring On All Needles:

• The rotary hook or needle plate area have burrs or rough areas.

• Rotary hook timing issue.