Wizcrafts,
Thanks for your prompt reply. The thread is not giving up at the needle, or breaking. It stays intact, unbroken, but somehow comes out of the needle, even though both ends of the thread are intact. I am using the same needles that I have used for a year, I changed the needle several times, and inspected the needles for failures using a microscope, but the needles appear to be fine. I know it sounds impossible, but it's happening. I'm an engineer and this has me baffled.
thanks,\
Bill