I haven't tried mine yet - but I thank all of your for your tips and thoughts!!

Luvtoquilt, Thanks for the tip. I love my cutter but hate to clean out the jibbles.

I want to thank everyone for all the great tips on this topic! It has been alot of help to me especially with those little pieces of flannel that gets down in the die.

I forgot to post a reply to this. I called Accuquilt and told them what was going on and they told me that the die needed to be replaced. The woman I spoke to was very nice and explained that sometimes the dies are made with the foam too thick and that can cause problems getting it through the machine. She said the popping and cracking I was hearing was not good so she arranged to have the die replaced.