Since Tartan first made this post I've been trying to pay attention to the conditions when it happens to me. I believe speed may be a factor for me, as well as possible tension issues.

Are you doing FMQ when this happens? My machine will do this when I move the quilt in what is a backward motion for the machine. Usually when moving up and to the left, if I remember right. It has to do with the way a stitch is formed. Sorry I can't give a full explanation, there is one online. Going fast in that direction makes it worse, but sometimes it happens even when I slow down. It usually shreds the thread also.

I can't speak for Tartan, but yes I am doing FMQ on my DSM, not a long arm. I'll have to pay even closer attention to see if it happens as you describe. Thanks!

You mentioned an explanation that's online? Do you have a link or the search terms used to find it? I would not even know how to describe what's happening.

And yes, shredded thread often.

I just had it happen again so I wanted to update this before I forget. I was going backwards and to the left as you thought Sue. Plus my bobbin was almost empty so that messes with the tensions. I am trying to pay close attention to the conditions when this happens.

Can someone explain though why it looks like there is more than one piece of thread in the needle? What on earth is happening?