Hassle-Free Tension With Acti-Feed™
Setting the right tension is imperative with embroidery. Did you know that Melco has a patented automated tension system so you don’t have to constantly adjust tension knobs? Acti-Feed™ is what sets Melco apart. Thread is fed through the machine based on your Acti-Feed™ settings and will automatically adjust while you’re sewing. This unique system was designed for you to spend less time messing with tension knobs, and more time focused on embroidery. Let’s dive into this innovative system and how it improves your stitching.
What is Acti-Feed™?
Acti-feed is a feature that replaces the tensioning system on a conventional embroidery machine. It uses thread feed gears and rollers to feed the desired amount of thread for each stitch. The amount of thread needed per stitch is dependent on material thickness.
Setting Acti-Feed™ In Melco OS (EMT16X, BRAVO, and older machines)
Acti-feed is set on the Melco SUMMIT by selecting your garment from the Acti-feed window on the touchscreen. Jump to the next section for more details. On models like the EMT16X and Melco BRAVO, Acti-feed can be set using Melco OS. Two modes are available that can be changed by clicking on the radio button to the left of the desired mode:
- Standard – Acti-feed feeds a user specified amount of thread per stitch.
- Auto – Acti-feed calculates and feeds the correct amount of thread fed per stitch.
Most of the Acti-feed system is automated based on sensor feedback. However, giving Acti-feed guidelines such as a minimum can help create higher-quality sew-outs.
Note: For your initial designs, and most designs, Auto mode will work best.
The default value for the material thickness field is 4 points, but if running in standard Acti-feed mode, you will need to adjust it to match your material. It can be adjusted to values ranging from 0 to 40 points. See the material thickness section below for more information on what value to use.
Standard Acti-Feed™
Standard Acti-feed is used to feed thread at a user specified amount. It will not feed more or less thread than the amount specified.
The amount can be adjusted by clicking on the up or down arrows to the right of the number. The number represents the material thickness.
The default value for the material thickness field is 4 points, but if running in standard Acti-feed mode, you will need to adjust it to match your material. It can be adjusted to values ranging from 0 to 40 points. See the material thickness section below for more information on what value to use.
Auto Acti-Feed™
Auto Acti-feed is used to feed thread based on feedback from the thread sensor bar. This allows the machine to change the material thickness number as it is sewing to reflect changes in the material. As the product being embroidered changes thickness, the thread dynamic changes and is reflected by the sensor. The sensor sends information back to the software, and the material thickness number is automatically adjusted. The changes in the material thickness are depicted in the moving graph just below the settings in the advanced tab.
As the machine embroiders, this chart will show a history of the Acti-Feed. This can be used to help diagnose thread breaks, false breaks, and sew quality issues. When the minimum is set appropriately on an even material, the feed activity will only be making minor adjustments. See the material thickness section below for more information on what value to use. Large adjustments in feed tend to indicate shifts in material, embroidery, or potential problems.
This mode is ideal for any material or application that changes thickness. For example, it would be good to use for caps with seams or jackets with appliqué. While auto mode was designed for materials that change thickness, it works well with most materials.
Note: Bobbin case cleanliness and differences in bobbin tension can affect the Acti-Feed.
Acti-Feed™ Settings on the Melco SUMMIT
While much of Acti-Feed is automated based on sensor feedback, giving Acti-Feed guidelines such as a minimum can help create higher-quality sew-outs on the Melco SUMMIT.
Suggested Settings
The Acti-Feed Suggestions can provide a guideline for where the minimum should be set.
Tapping any fabric/garment suggestion populates the slider and Acti-Feed Minimum to a mid-point suggestion for that material. As even the same type of garment can vary in thickness, you may wish to adjust the Acti-Feed Minimum a bit more. Learn more in this in-depth article.
Feed Chart
This chart helps monitor the feed of thread to the product. It displays the following:
- Feed – This is the amount of thread being fed to account for the detected material thickness.
- Minimum – Displayed as the lower user-adjustable line. This represents the lowest the Acti-Feed is allowed to go.
- Maximum – Displayed as the upper user-adjustable line. This represents the highest amount the Acti-Feed is allowed to go without modifiers/effects in the color sequence.
As the machine embroiders, this will show a history of the Acti-Feed. This can be used to help diagnose thread breaks, false breaks, and sew quality issues. When the minimum is set appropriately on an even material, the feed activity will only be making minor adjustments. Large adjustments in feed tend to indicate shifts in material, embroidery, or potential problems.
Note: Bobbin case cleanliness and differences in bobbin tension can affect the Acti-Feed.
Material Thickness
Material thickness is a determining factor in the amount of thread fed for each stitch. On the Melco SUMMIT, the perceived material thickness is displayed as the current feed value in the Feed Chart. On all other Melco machines, it is displayed under “Acti-feed” in the Status Tab and the Advanced Status Tab on Melco OS. It can also be found in the Thread Feed Tab. Material thickness is measured in points. In this and many embroidery software applications, a point is used as a fine unit of measure representing a tenth of a millimeter.
Calculating Material Thickness Example
You can calculate an exact Acti-Feed minimum if calipers are available to measure the actual thickness of the material and stabilizer. The result can then be converted to points (1 millimeter = 10 points).
For example, you might measure the thickness of a cap being readied for a puff application to be 4.2 millimeters (mm):
- 1 mm for the structured cap
- 0.2 mm for 1 piece of tear-away stabilizer
- 3.0 mm for a piece of 3 mm puff foam
A 4.2 mm thickness converts to 42 points (pts). Subtracting two would result in a recommended Acti-Feed minimum of 40 pts.
Choosing Appropriate Settings
Auto Acti-feed automatically adjusts for different garment thicknesses. You can however provide some guidance in the form of lower and upper limits. This will provide a range in which auto Acti-feed must operate. Finding just the right settings or limits for your Acti-feed is not always necessary, but it can make a marked improvement in sew quality and machine performance.
Minimum
The Acti-feed Minimum sets a lower limit for the Acti-feed. It allows the machine to adjust the amount of thread fed as needed, but it will not allow feeding of less than the specified amount. While typically used with thicker materials, the lower limit (Minimum/Preset) is helpful when dealing with more delicate or squishy materials. It is helpful where the thread could pull tight, but a little more loft is desired.
The ideal setting for the minimum is the actual thickness of the material (and stabilizer) being sewn, minus two points. The following settings are suggestions for a variety of common fabric and backing combinations. These settings may need to be adjusted as material weights can differ.
|
Material |
Acti-Feed Minimum |
|---|---|
|
Broadcloth with cut-away backing |
3-4 |
|
T-Shirt with 2 pieces of cut-away backing |
3-5 |
|
Polo shirt with cut-away backing |
4-8 |
|
Towel with tear-away backing |
6-20 |
|
Unstructured cap with tear-away backing |
4-8 |
|
Structured cap with tear-away backing |
8-12 |
Acti-Feed Minimum Value is Adequate When…
- Satin and Fill stitches – There is no looping or pulling on the top of a sew-out when sewing satin and fill stitches.
- Satin stitches – On the back side of the sew-out, the column is made up of bobbin for approximately ⅓ down the middle. The top color makes up the remainder on the sides.
- Fill Stitches – On the back of the sew-out, the top thread is even along the outer edge of the shape.
Maximum
The Acti-Feed Maximum sets an upper limit for the Acti-Feed. It allows the machine to adjust the amount of thread fed as needed, but it will not allow feeding more than the specified amount. It is uncommon to need to limit the maximum for the Acti-Feed.
Acti-Feed Troubleshooting
Sew quality issues and thread breaks can be indicators of inappropriate thread feed. Those symptoms are listed in the sections below.
Increase Acti-Feed Minimum Value When…
When too little thread is being fed into the design, you may experience the following problems:
- Satin stitches – You encounter thread breaks and can see bobbin thread on the top of the design.
- Satin stitches – Too much bobbin is showing on the back of the design.
- Fill stitches – You can see bobbin thread on the top of the design.
- Fill stitches – There is insufficient top thread showing on the back of the design.
- Registration Loss – If designs are not lining up when sewn and the cause is the thread being pulled way too tight, increasing the Material Thickness may help. Use a stable support material for additional help.
If you are experiencing these problems, you may need to increase the Acti-Feed Minimum to increase the amount of thread being fed.
Decrease Acti-Feed Minimum Value When…
When too much thread is being fed into the design, you may experience the following problems:
- Satin stitches – The stitches in the design are looping.
- Satin stitches – Not enough bobbin is showing on the back of the design.
- Fill stitches – You encounter thread breaks, and the stitches in the design are looping.
- False Bobbin Breaks – When the software falsely detects bobbin breaks that are not truly broken thread, it could be that your material thickness is too high.
If you are experiencing these problems, you may need to decrease the Acti-Feed Minimum to decrease the amount of thread being fed.