Bird Nesting Issue Resolved Through Bobbin Cleaning and Machine Maintenance

The client noticed:
• bird nesting underneath the fabric
• loose top stitches
• thread bunching during the white fill area
The green outline stitched properly, but the denser white section kept causing problems during every test run.

After reviewing the stitch-out photos and discussing the setup, the embroidery file itself did not look like the main problem. The green outline stitched cleanly, which showed the design itself was sewing properly.
The issue was only happening during the denser white fill area, which pointed more toward:
• lint or dust inside the bobbin case
• thread tension issues
• thread not feeding smoothly
• machine setup or maintenance problems
Because this was a very small blazer lapel design, even small tension problems became more noticeable during the heavier white stitching.

• Reviewed the stitch-out shared by the client
• Checked which parts of the design stitched correctly
• Recommended machine troubleshooting before changing the file
• Asked the client to clean the bobbin case
• Suggested blowing out lint and dust with air
• Recommended changing to a fresh bobbin
• Discussed density reduction only as a backup option if needed

After cleaning the bobbin case, blowing out the lint, and replacing the bobbin, the design stitched properly without needing major file changes.
This confirmed the issue was mainly caused by:
• lint affecting the bobbin movement
• unstable thread tension
• poor thread feeding during the dense white stitching
The embroidery file itself was working correctly because the green outline already stitched cleanly. Once the machine setup was cleaned and stabilized, the bird nesting disappeared and the white fill stitched normally.