I had the same thing happen to me a year or so ago...only it did that WHILE I was ironing and it burned up the fabric!!!!!!!!! SCARY! I bought a cheap $35.00 iron that has worked real well. Then the other day, someone on this board said they use their travel iron!!! WOW! I have one! So I have the ironing board set up with big iron for big things, and my travel iron and travel board set up next to my machine for the small stuff. Sure saves me steps!