I'm making flannel stars and sewing together small pieces of flannel fabric stitching from corner to corner. The problem I'm having is that the needle pushes the fabric down into the throat hole, gumming up the works and breaking the thread. I'm using a size 80/12 universal needle (new) and cotton thread. Is there a way to prevent this from happening? And why is it happening? It seems to be a problem with the flannel, because I can't recall this happening with regular fabric. Any ideas would be appreciated. Maybe there's some technique I'm unaware of?

Have you ever sewn with a leader fabric

here is a video to watch and I use it all the time now when sewing

http://www.youtube.com/watch?v=nTBPjlm1_44

A straight stitch plate also works wonders, so I hear.

Do you have a center-hole plate for your machine? It won't allow the fabric to be sucked in (yes, my machine does the same - even with a leader to start). My mother-in-law said that she uses wax paper as a leader and rips it off later. I have not tried that.

Your needle might be to thick and the point might be too round???? (guessing here).

It's frustrating for sure.

Try the leader fabric. Or sometimes I start the fabric in about a stitch or two.

if the pieces are really small, try a tear-away interfacing.

You can use paper, or used dryer sheets, coffee filters or any tear away interfacing to start the seam with. Just tear it away when done.

Leader fabric.

leader and a sharp needle instead of universal

sharp needle and start down farther if you can