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Hello, thanks for the help.

Got a quick question, as I'm looking for a new embroiderer since mine is retiring, I noticed her competition has really gotten good. Their hats don't have the single thread tailing off from one letter to the next like hers.

Why do some embroiderers have that one thread linking each letter, number, etc..., and some don't?
 

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I don't know if I would say that. Sometimes the choice to leave the jump stitch between small letters is a matter of efficiency. On a small left-chest logo with a bunch of little letters it's easier to leave that stitch in there as it's not really noticeable except up close and then the machine doesn't have to do any trims. On a bigger stitchout where the letters may be spread out a little then a good digitizer will do a trim at each letter.
 

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Before cutting connector stitches I would make sure there is a lock stitch at the end of each letter or else you might have stitches pullout.

You can request to have lock stitches (therefore no connector stitches) between characters within a word but it will slow down your run and you’ll be more likely to have pullouts if you machine has to constantly stop and start again. Many digitizers space letters close to each other (artwork permitting) so connecting stitches are less visible. Sometimes the artwork requires letters to be spaced so connector stitches shouldn’t be used.
 

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A really good digitizer/production operation will combine both jump stitches trims and manually created jumps to try to balance efficient production time and quality.

If I am anticipating needing to trim jump stitches I will actualy adjust the order of operations and create a long or manual jump stitch that is easier to get a good hand trim on without tweezers.
 

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Often times a jump stitch will be more appealing/less ugly than the knotting of a tie off or lock stitch on certain letters. You also run into knotting pulls on some fabric when using tie offs. instead of pulling the loose thread tail through the fabric the loose tail will get stuck and pull on the fabric/stitching. Usually in combination with very small/dense satin stitches
 
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INKJESS - You wrote "probably using an older digitiser maybe, or cheaper one". A digitizer is someone who creates an embroidery file from art, using software. The digitizer determines whether or not there will be jump stitches between objects (or letters) in a design. There are many software programs that digitizers can use and most professional software allow a digitizer to set the stitch length at which an automatic trim will take place. If you don't want jump stitches, tell your digitizer. As noted by others, it takes longer to trim than to use a jump stitch and tying knots after a trim can affect the quality of the embroidery on some fabrics.
 
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