Just some ideas I mite throw at you. Are you using regular quilting needles. They make needles for quilting. They are shorter, I don't know for a fact that they are stronger, but I'm assuming they are. Since we're going through 3 thickness's. Also is your quilt frame to taught, If not using quilting needles, are the needles your using to long? Some people can't use quilting needles because they suffer from arthritis in their hands, or eyesight is poor. So they use a longer needle. I don't suffer from these aliments (Yet). However I use a longer needle because I feel uncomfortable using the quilting needles. Again it may be the quality of needle that you are using. Maybe try another Brand and I'm sure they are alittle bit more expensive. These are some of my ideas. When in dout go on the board and ask Boo. She's full of info. Good Luck and Happy Quilting.