machine not detecting thread break, continues to sew

[Tricia]

Couple things going on with this job. The thread keeps coming out of needle, even up through the needle bar etc. Only the one color in this logo is giving me problems-I've switched the needle, switched the thread to another needle, even ran a different job with no problems (I figured if it was trim/knife related, it would show up while running the other job)---Leading me to believe possibly the digitizing?? Regardless, the machine is not stopping when the thread comes out, it sews 1 or 2 more letters before it detects no thread. I've checked that the Enable Thread Detection box is checked, yep, always is.
I really sick of re-threading the needle, almost once per shirt.

Any insights are much appreciated as always.

I've read older posts but didn't find a similar problem.

Thanks,
Tricia

[Mama Kass]

Have you watched this happen? Is it possible that the particular thread (the one that is coming out of the needle) was used previously in the design and didn't cut properly, thus breaking and snapping out of the needle when moving to another needle? Figuring out at what is happening when the thread is coming out will give us more info to go on.
Also, sometimes the thread detection will not notice the break for a while if there is still tension on the sensor for a while after coming unthreaded. If the letters are small, lack of immediate thread break detection wouldn't surprise me; if we're talking about thousands of stitches, that's a different story.