I had a similar problem with the needles breaking with my Brother and after several hours my repairman and I found the problem. Depending on the underlayment quality and stitch density of the pattern you simply cannot enlarge/ resize some embroidery patterns without running into this problem. This was the first time in over 40 years my repairman had run into this problem and he said it has to do with the fact that a lot of the designs are now auto digitized which creates inferior designs and resizing problems. You didn't say whether or not you had changed the size of the design......if so, this may be your problem.