just a thought..... have you compared the underside of your embroidery to what is considered "normal" for your machine? You should be able to find this in your instruction manual.
Perhaps your bobbin tension is too tight or conversely your needle tension can be too tight.
I have one machine that I always have to loosen the needle tension by two points and the other machine (identical brand and model to machine one), needs the needle tension loosened one point for each design.
Also two machines prefer one brand of bobbin thread , while a third machine doesn't like that brand at all and will only stitch well with Brother bobbin thread.
Same thing applies to using different brands of needles.
Just little idiosyncrasies that I need to remember.
There are so many variables that can affect your stitchouts, it probably would help if you could provide a little more information on your needle size, type and weight of thread and fabric, the better help you.
Hugs n roses, Meganne
Also after hooping, don't tug on the fabric outside of hoop to make it taut. When you do this, fabric is distorted and can't be seen until fabric is un-hooped.
Hmmm...lots of suggestions, but I agree, we still need a bit more information about the design and fabrics you are using...depending upon design and fabrics...I sometimes iron on a product like Jenny Hasking Sheer Magic to stabilize the fabric before I embroider...or I also will starch the fabric several times with a spray starch to get it stiff...this also helps to eliminate puckers and will wash out cleanly. When you starch, spray one side...then turn the fabric over so the starch is toward the ironing board...then press...then repeat...If you press the side you sprayed the starch on...you get little white flakes of starch and the starch does not go into the fabric...by turning the sprayed side toward the ironing board, the heat will press the starch into the fabric and no white flakes to worry about...
I did not know this.. .always wondered how to get rid of those little white flakes!! Thanks!
If your design is over 10,000 stitches, try "floating" a second layer of stabilizer under your hoop after it's set on your machine and before stitching. Also, if your fabric has stretch in it, you need to use a different kind of stabilizer (cutaway) that will keep the stitches from stretching with the fabric and distorting and breaking.
Sarah and Karen are right -- we do need more information.
Some general ideas:
Sometimes the design is too dense for the fabric. Many digitizers create designs with specific fabric in mind.
If the digitizer is new to digitizing or the design was auto-digitized...there may be nothing you can do. As the threads are stitched into the fabric, they pull on the fabric. If adjustments are not made then you end up with a puckered mess.
Did the digitizer show a stitched out version of the design? I have seen many digitizers show puckered results with their own test designs.
Hmmm, are hooping your fabric too tightly? Sometimes with dense designs I need 2 layers of stabilizer, especially if the fabric is a lightly woven fabric. Keep telling us more and include pictures. Pictures are a huge help.
Is the design very dense? I know that a dense design often causes problems. Perhaps a picture of what you are sewing might help. Sarah