How to Fix Bird Nesting on the E15 Embroidery Machine
Written by Tia Isom
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Published on
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Modified on
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Reading time for 6 min
Introduction
If a large amount of thread bunches up on the back of the fabric, that’s commonly known as bird nesting. It’s one of the most common embroidery problems, and it almost always happens because something along the thread path or in the hoop setup is out of balance.
The good news: bird nesting is rarely caused by a broken machine. In most cases, one of seven checkpoints has gone wrong — and you can fix them all at home on your embroidery machine. This guide walks through the same troubleshooting sequence our support team uses, in the order that catches the most likely causes first.
Stop the machine immediately when you see bird nesting, then follow these steps:
Bird nesting is thread bunching on the back of the fabric — not a machine failure.
Stop the machine immediately. Do not keep stitching over tangled thread.
The seven checkpoints: tangled threads, upper thread path, upper tension, bobbin, needle, hooping/stabilizer, and design density.
Loose upper tension and incorrect bobbin direction are the two most common causes.
Test every fix at low speed on scrap fabric before resuming the real project.
Never shrink an embroidery design by more than 10% — high stitch density triggers bird nesting.
Step 1: Remove the Tangled Threads
First, cut the tangled threads from underneath the hoop. Leaving them in place will make the next steps harder to judge and can damage the fabric or the rotary hook.
Then remove the needle plate cover by following the instructions in the E15 user manual.
Carefully use needle-nose pliers or small scissors to remove the tangled thread from underneath the needle plate and around the rotary hook.
Before reinstalling the cover: make sure no thread is blocking the rotary hook. Even a small strand left behind will cause the same problem again within seconds.
Step 2: Check the Upper Thread Path
Make sure the thread passes through every thread guide and tension component correctly, without tangles or feeding resistance. A missed guide is easy to overlook but will throw off tension on the entire stitch.
Follow the thread from the spool all the way to the needle. Every guide should be threaded, and the thread should sit cleanly inside each one — not looped around the outside.
Step 3: Check the Upper Thread Tension
Upper thread tension that is too loose can also cause bird nesting. If the upper tension is loose, the bobbin thread pulls the upper thread down through the fabric, creating a tangle on the back.
Slightly tighten the thread guide tension discs, making only small adjustments each time.
Then test the machine at a low speed on scrap fabric. If bird nesting still appears, tighten by one more small step and test again. Do not make large jumps — tension changes are cumulative.
Step 4: Check the Bobbin Installation
Remove the bobbin case and reinstall the bobbin. Make sure the bobbin is installed in the correct direction, and that the thread is properly seated underneath the bobbin case tension spring.
An incorrectly oriented bobbin is one of the most common causes of bird nesting — and one of the easiest to miss. The thread should pull smoothly with light resistance when you tug it, not free-spin.
Step 5: Check the Needle
Next, inspect the needle. Make sure it is installed correctly and is not bent, worn, or damaged.
A bent, worn, or damaged needle can cause thread bunching, skipped stitches, and design misalignment. Replace it if you see any sign of damage — do not try to straighten a bent needle.
Step 6: Check the Hooping and Stabilizer
Also, check that the fabric is hooped firmly, and that you are using the appropriate stabilizer.
If the fabric is too loose, rehoop it. Add an extra layer of stabilizer when additional support is needed — especially for stretchy or lightweight fabrics.
Step 7: Check the Embroidery Design
If bird nesting repeatedly happens at the same point in the design, the stitches may be too dense or too short. Optimize the embroidery file, then run another test at a lower speed.
The E15 Embroidery Machine is supported by IdeaStudio software, which can scale embroidery designs up or down. When you shrink a design too much, stitch density becomes too high, which makes bird nesting more likely. In that case, scale the design up slightly to restore the correct stitch density, and the bird nesting problem is solved.
Recommendation: Do not scale embroidery designs by more than 10% in either direction. Beyond that, stitch density shifts enough to affect the final result.
Tutorial Video
If you prefer to follow along visually, the video below walks through the same seven checkpoints in order — from removing tangled threads to adjusting the design scale. You can watch it before you start or use it alongside the steps above.
Watch the full bird nesting troubleshooting walkthrough on the HTVRONT E15 Embroidery Machine.
Conclusion
Bird nesting is frustrating, but it’s almost always fixable at home. The seven checkpoints in this guide — tangled threads, upper thread path, upper tension, bobbin direction, needle condition, hooping and stabilizer, and design density — cover the causes behind the vast majority of cases.
Start with Step 1, work through the list in order, and test each fix at low speed on scrap fabric before returning to your project. If bird nesting still happens after all seven checks, contact HTVRONT Support at support@htvront.com — there may be a mechanical issue that needs professional attention.
Bird nesting is when a large amount of thread bunches up on the back of the fabric during embroidery. It typically happens because upper tension is too loose, the bobbin is installed incorrectly, or the needle and hoop setup is off balance.
Should I keep stitching when I see bird nesting?
No. Stop the machine immediately. Continuing to stitch over tangled thread can damage the fabric, break the needle, or jam the rotary hook. Remove the tangled threads first, then work through the seven checkpoints in this guide.
What’s the most common cause of bird nesting?
The two most common causes are loose upper thread tension and an incorrectly installed bobbin. Check these first — they’re the easiest to fix and account for most cases.
Can scaling down an embroidery design cause bird nesting?
Yes. Shrinking a design increases stitch density, which makes bird nesting more likely. Scale the design back up to restore the correct density. We recommend not scaling designs by more than 10% in either direction.
How do I test whether the fix worked?
Run the machine at low speed on scrap fabric before resuming your real project. Low-speed testing reveals tension problems more clearly and prevents wasting fabric on a fix that isn’t complete.
What if bird nesting keeps happening after all seven checks?
If bird nesting persists after working through all seven steps, contact HTVRONT Support at support@htvront.com. There may be a mechanical issue — such as a damaged rotary hook or timing problem — that requires professional service.
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