Brother PE545 Common Problems and Troubleshooting

In this comprehensive article, our focus is on exploring potential issues that may arise while using the Brother PE545 sewing machine. Alongside these challenges, we are dedicated to presenting practical and effective solutions to address them.

Our primary objective is to provide valuable assistance in troubleshooting any problems that might occur during your sewing projects with this particular machine.

The Brother PE545 sewing machine is renowned for its versatility and feature-rich capabilities, empowering your creativity and precision in crafting breathtaking designs. Nevertheless, like any advanced equipment, it is only natural to encounter occasional hiccups during its operation.

We understand the frustration that such difficulties can bring, especially when you are deeply immersed in your sewing projects. But, rest assured, we are here to fully support you throughout the troubleshooting process.

Brother PE545 Overview

The Brother PE545 embroidery machine is a powerful tool that lets you explore your creativity with ease. With its 4″ x 4″ embroidery field and 135 built-in embroidery patterns, including various designs for kids, holidays, and florals, this machine offers endless possibilities for customizing your creations.

The 10 built-in fonts allow you to add personalized lettering and monograms to your projects, giving them a unique touch. The large 3.7-inch LCD color touchscreen provides a user-friendly interface to drag and drop your embroidery patterns, make edits, and preview your designs before stitching.

Additionally, the PE545 comes with the Artspira mobile app, enabling you to create custom embroidery patterns directly from your mobile device.

Product Details and Features:

MaterialPlastic, Metal
Product Dimensions16.5″D x 7.76″W x 12.09″H
Item Weight1 Pound
Power SourceAC
Is ElectricYes

Key Features:

  • Transmit embroidery files wirelessly from your PC to the machine using Design Database Transfer software.
  • Use the Artspira mobile app to create custom embroidery patterns on your mobile device and transfer them wirelessly to the PE545.
  • 4″ x 4″ embroidery field with included hoop for various project sizes.
  • Large 3.7-inch LCD color touchscreen for easy design manipulation and preview.
  • 135 built-in embroidery designs, including kids’ designs, holiday themes, florals, and more.
  • 10 Built-in fonts (7 English and 3 Japanese) for personalized lettering and monogramming.
  • Comes with various accessories to get you started on your embroidery journey.
  • Intended for sale only in the US at 120 volts, using electric power.
  • This is an embroidery-only machine and does not function as a traditional sewing machine.

Causes of Common Problems with the Brother PE545

In the following subsections, we will address possible problems that users might encounter while using the Brother PE545 embroidery machine and provide troubleshooting tips to resolve these issues effectively.

Common Problems with the Brother PE545

Problem 1: Thread Breaks During Embroidery

Description: One common issue with the Brother PE545 is the thread frequently breaking while embroidering.

Cause: There can be several reasons for thread breakage, such as incorrect threading, using low-quality or old thread, a damaged needle, or the tension being too tight or too loose.


  • Double-check the threading path to ensure the thread is correctly threaded through all guides and the needle.
  • Use high-quality embroidery thread that is suitable for the Brother PE545 machine.
  • Replace the needle regularly to avoid using a damaged or worn-out needle.
  • Adjust the thread tension gradually, trying slightly tighter or looser settings to find the optimal tension for your project.

Problem 2: Misaligned Embroidery Designs

Description: Another common issue is when the embroidery designs are not aligning correctly on the fabric, resulting in distorted or off-centered patterns.

Cause: Misaligned designs may occur due to improper hooping, incorrect design placement in the embroidery software, or a need for calibration.


  • Ensure the fabric is firmly hooped and straight to prevent shifting during embroidery.
  • Double-check the design placement in the software and make any necessary adjustments before starting the embroidery process.
  • Calibrate the embroidery machine following the manufacturer’s instructions to ensure precise design alignment.

Problem 3: Skipping Stitches in Embroidery

Description: Some users may encounter issues where the machine skips stitches while embroidering, resulting in incomplete designs.

Cause: Skipping stitches can be caused by a dull or damaged needle, improper tension, or incorrect design digitization.


  • Replace the needle with a new and appropriate needle for embroidery.
  • Adjust the thread tension as per the manufacturer’s recommendations to prevent skipped stitches.
  • Check the design file for any issues and re-digitize it if necessary before attempting to embroider again.

Problem 4: Embroidery Machine Jamming

Description: The Brother PE545 may experience jamming or become unresponsive during embroidery.

Cause: Machine jamming can occur due to tangled thread, a bent needle, debris in the bobbin area, or a software glitch.


  • Stop the machine immediately and turn it off to avoid further damage.
  • Carefully remove the hoop and check for any tangled thread or debris in the bobbin area.
  • If the issue persists, rethread the machine, replace the needle, and restart it.
  • If the problem continues, perform a factory reset or update the machine’s software as a last resort.

Problem 5: Incorrect Embroidery Colors

Description: Some users may encounter situations where the embroidered colors do not match the selected ones in the design.

Cause: Incorrect embroidery colors can be the result of misalignment between the software and the machine’s thread chart, or using the wrong thread spools.


  • Verify that the thread colors in the design file match the thread chart of the Brother PE545 machine.
  • Use high-quality thread spools from reputable brands to ensure accurate color reproduction.
  • Calibrate the machine if necessary to improve color matching.

Problem 6: Uneven Embroidery Stitching

Description: Users may notice that the embroidery stitches appear uneven or irregular in some areas.

Cause: Uneven stitching can be caused by tension inconsistencies, incorrect stabilizer usage, or an issue with the embroidery machine’s timing.


  • Ensure the thread tension is correctly set for the type of fabric and design being used.
  • Use the appropriate stabilizer to provide adequate support and prevent fabric distortion during embroidery.
  • If the issue persists, consult a professional technician to check and adjust the machine’s timing.

Problem 7: Bobbin Thread Showing on the Top

Description: Some users may notice the bobbin thread showing on the top of the embroidery, ruining the design’s appearance.

Cause: This issue often occurs due to incorrect bobbin tension or using an inappropriate bobbin thread.


  • Adjust the bobbin tension following the machine’s manual instructions to achieve balanced stitching.
  • Use high-quality bobbin thread that matches the thread weight and type used for the top embroidery.

Problem 8: Embroidery Machine Not Reading USB Drive

Description: The Brother PE545 may encounter difficulties in reading or recognizing a USB drive when trying to import designs.

Cause: This problem may be due to an incompatible file format, a corrupted USB drive, or issues with the machine’s USB port.


  • Ensure the design file is in a supported format such as .PES and is compatible with the PE545 model.
  • Try using a different USB drive or reformat the existing one to eliminate any corruption issues.
  • Check the USB port for any damage or debris and clean it if necessary.

Problem 9: LCD Touchscreen Malfunction

Description: Users may experience unresponsiveness or glitches with the LCD touchscreen, making it difficult to navigate and use the machine.

Cause: LCD touchscreen issues can result from firmware glitches, physical damage, or an accumulation of dust and debris.


  • Restart the machine to see if the touchscreen responsiveness improves.
  • If the problem persists, check for any physical damage to the screen and contact customer support for repairs or replacement.
  • Clean the touchscreen gently with a soft, lint-free cloth to remove dust and debris.
  • Ensure that the machine’s firmware is up-to-date by checking the manufacturer’s website for updates and instructions.

Problem 10: Embroidery Design Not Stitching Out Properly

Description: Some users may encounter issues where the embroidery design does not stitch out accurately, leading to incomplete or distorted patterns.

Cause: Problems with stitching can arise from a damaged design file, insufficient hoop tension, or incorrect needle choice.


  • Check the design file for any errors or corruption, and re-download or re-digitize the design if needed.
  • Ensure the fabric is adequately hooped and secured to prevent any movement during the embroidery process.
  • Use the correct needle size and type for the chosen fabric and design to improve stitch quality.

Problem 11: Bobbin Winding Difficulties

Description: Users may face challenges while winding the bobbin, resulting in unevenly wound bobbins or thread tangles.

Cause: Bobbin winding issues can occur due to improper threading, incorrect bobbin placement, or a malfunctioning bobbin winder.


  • Ensure the bobbin is correctly placed on the winding spindle and that the thread is securely threaded through the bobbin winding path.
  • Check for any obstructions or tangles in the bobbin winding mechanism and remove them if present.
  • If the issue persists, contact customer support for further assistance or a possible bobbin winder replacement.

Problem 12: Thread Nesting on the Bottom

Description: Thread nesting, also known as bird’s nesting, occurs when excess thread accumulates on the bottom side of the fabric, causing thread tangles and messy embroidery.

Cause: This issue may result from incorrect tension settings, using low-quality thread, or not properly securing the fabric in the hoop.


  • Check and adjust the upper thread tension to achieve balanced stitching.
  • Use high-quality embroidery thread to reduce the chances of thread nesting.
  • Ensure the fabric is tightly secured in the hoop to prevent movement during embroidery.

Problem 13: Limited Design Compatibility

Description: Some users may encounter limitations in using certain embroidery design formats or find compatibility issues with specific design files.

Cause: Design compatibility problems can arise from using unsupported file formats or designs that are too complex for the machine’s capabilities.


  • Ensure that the embroidery design file is in a format supported by the Brother PE545, such as .PES.
  • If a design is too complex, consider simplifying it or breaking it down into smaller segments for embroidery.
  • Update the machine’s firmware to the latest version to improve design compatibility.

Problem 14: Noisy Operation

Description: The Brother PE545 may produce unusual noises during operation, which can be bothersome and indicate potential issues.

Cause: Noisy operation may result from loose parts, a misaligned mechanism, or inadequate lubrication.


  • Inspect the machine for any loose screws, parts, or accessories, and tighten them as necessary.
  • Apply a small amount of sewing machine oil to the moving parts as recommended in the user manual.
  • If the noise persists, contact customer support for professional inspection and repairs.

Problem 15: Thread Fraying or Breaking at Needle

Description: Thread fraying or breaking at the needle can disrupt the embroidery process and lead to incomplete designs.

Cause: This problem may occur due to using a needle with a small eye, using the wrong needle type for the fabric, or thread tension issues.


  • Use a needle with a larger eye to accommodate the embroidery thread and prevent fraying.
  • Select the correct needle type and size based on the fabric’s weight and texture to avoid unnecessary thread stress.
  • Ensure the thread tension is appropriately set to prevent excessive strain on the needle.

Problem 16: Thread Jamming in the Bobbin Area

Description: Thread jamming in the bobbin area can lead to the machine’s inability to move or produce uneven stitches.

Cause: This problem may result from using low-quality thread, incorrect bobbin winding, or a dirty bobbin case.


  • Use high-quality embroidery thread that is suitable for the Brother PE545 machine.
  • Ensure the bobbin is correctly wound and placed in the bobbin case to prevent jamming.
  • Regularly clean the bobbin case and surrounding area to remove dust and lint that can cause thread jams.

Problem 17: Uneven Feed Dogs Movement

Description: Uneven feed dog movement can result in fabric bunching or not advancing smoothly during embroidery.

Cause: The issue may occur due to dirt or debris clogging the feed dogs, or the feed dog mechanism needing adjustment.


  • Clean the feed dogs and the area around them to ensure smooth fabric movement.
  • If the feed dog mechanism is adjustable, refer to the user manual for instructions on proper calibration.
  • If the problem persists, contact customer support or a professional technician for further assistance.

Problem 18: Embroidery Needle Breakage

Description: Users may encounter issues where the embroidery needle frequently breaks during stitching.

Cause: Needle breakage can occur due to using the wrong needle size or type, a damaged needle, or stitching through thick fabric without proper adjustments.


  • Ensure you are using the correct needle size and type for the fabric and design being embroidered.
  • Replace the needle regularly, especially if it shows signs of wear or damage.
  • If embroidering on thicker fabrics, reduce the machine’s speed and consider using a heavier needle to prevent breakage.

Problem 19: Inconsistent Thread Tension Across Designs

Description: Users may notice variations in thread tension across different embroidery designs, leading to uneven stitch quality.

Cause: Inconsistent thread tension can result from not adjusting the tension settings appropriately for each design or using different thread types.


  • Before starting a new design, reset the thread tension to the default setting and make adjustments based on the fabric and design requirements.
  • Use the same type and weight of thread for each design to maintain consistent tension throughout the embroidery process.
  • Practice stitching test designs on similar fabric to fine-tune the thread tension before embroidering the final project.

Problem 20: Software Connectivity Issues

Description: Users may encounter difficulties when trying to connect the Brother PE545 to embroidery software or transfer designs via USB.

Cause: Connectivity problems may arise from outdated software, incompatible drivers, or issues with the USB port.


  • Ensure the embroidery software is up-to-date and compatible with the Brother PE545.
  • Install the necessary drivers for the machine and update them if required.
  • Check the USB port for any damage or debris and clean it if necessary.

Problem 21: Slow Embroidery Speed

Description: Some users may experience slow embroidery speed, which can significantly extend the time required to complete projects.

Cause: Slow embroidery speed can result from incorrect machine settings, an overloaded design, or insufficient memory.


  • Adjust the embroidery machine’s speed settings to the desired level without compromising on stitch quality.
  • Simplify complex designs or break them down into smaller sections to reduce processing time.
  • Free up memory space by removing unnecessary designs or files from the machine’s internal memory or connected USB drive.

Problem 22: Thread Puckering or Gathering

Description: Thread puckering or gathering occurs when the fabric around the embroidered area becomes distorted or forms unsightly wrinkles.

Cause: This issue may be caused by excessive tension, using the wrong stabilizer, or insufficient hoop support.


  • Adjust the thread tension to find the optimal balance for your fabric and design.
  • Use the appropriate stabilizer for the fabric to provide the necessary support during embroidery.
  • Ensure the hoop is tight enough to hold the fabric securely without causing tension around the embroidered area.

Problem 23: Thread Shredding or Fuzzing

Description: Users may encounter issues where the embroidery thread shreds or produces fuzzy fibers during stitching.

Cause: Thread shredding can occur due to using old or low-quality thread, using the wrong needle type, or a buildup of lint in the machine.


  • Use high-quality embroidery thread that is suitable for the Brother PE545 machine.
  • Ensure the needle type matches the fabric’s weight and texture to prevent excessive thread shredding.
  • Clean the machine regularly to remove lint and debris that can cause thread fuzzing.

Problem 24: Hoop Alignment Issues

Description: Users may encounter problems with the alignment of the hoop, leading to misaligned embroidery designs.

Cause: Hoop alignment issues can result from an improperly secured hoop or a misaligned embroidery arm.


  • Ensure the hoop is correctly and securely attached to the embroidery arm before starting the embroidery process.
  • Check for any debris or obstructions that might hinder the hoop’s smooth movement and clean the area if necessary.
  • If the hoop alignment issue persists, consult the machine’s user manual for instructions on proper hoop calibration.

Problem 25: Limited Technical Support

Description: Some users may encounter difficulties in accessing timely technical support or troubleshooting resources for the Brother PE545.

Cause: Limited technical support may arise from outdated or insufficient customer service resources or a lack of easily accessible information.


  • Visit the official Brother website for online resources, FAQs, and software updates related to the PE545 model.
  • Contact Brother customer support via phone or email for personalized assistance with specific issues.
  • Join online forums or user groups dedicated to the Brother PE545 to seek advice and troubleshooting tips from experienced users.

Brother PE545 Sewing Machine User Reviews

Positive Reviews from Brother PE545 Sewing Machine Users

  • Many users were satisfied with the ease of use of the Brother PE545. They mentioned that the machine’s setup and navigation were straightforward, allowing them to start embroidering quickly and efficiently.
  • Several users appreciated the versatility of the machine’s embroidery features. They found the 4″ x 4″ embroidery field, built-in designs, and font styles offered ample creative options for various projects.
  • Users were pleased with the wireless LAN capability, which allowed them to transfer embroidery files from their PC to the machine effortlessly.
  • Some customers mentioned the quality of the embroidery, stating that the stitches were neat and precise, resulting in professional-looking designs on different fabrics.
  • Many users praised the instructional materials and tutorials included with the machine, stating that they were helpful for beginners and those new to embroidery.

Negative User Reviews of the Brother PE545 Sewing Machine

  • Some users expressed disappointment with the machine’s automatic thread feature, mentioning that it broke after only a short period of use.
  • A few customers faced challenges with the machine’s software, particularly the limited compatibility and difficulty finding suitable software for their desired embroidery designs.
  • One user experienced difficulties with the machine’s registry site, leading to frustration and an inability to fully utilize the machine’s features.
  • Some customers were dissatisfied with the machine’s durability, reporting issues with its long-term performance and questioning its value for the price paid.
  • One user mentioned issues with the machine’s delivery, where it arrived in its factory box with a label slapped on it, reducing the surprise element for a Christmas present.

All information about user reviews is taken from Walmart.

Despite some negative feedback, the majority of users were satisfied with the Brother PE545 Sewing Machine, as evident from the numerous positive reviews praising its ease of use, versatility, wireless capabilities, and embroidery quality.

The machine’s instructional materials also received appreciation, making it an excellent choice for both beginners and experienced sewists.

Brother PE545 Common Problems
Brother LB5000M Common Problems
Brother SE2000 Common Problems

Brother PE545 Sewing Machine Manual

The operating instructions for the Brother PE545 Sewing Machine can be found on the manufacturer’s website. To access the manual, visit the official Brother website and navigate to the support section or search for the specific model.

The manual provides detailed guidance on setting up, using, and maintaining the sewing machine, ensuring optimal performance and trouble-free embroidery experiences.

Brother PE545 Frequently Asked Questions

Q1: How do I import embroidery designs into the Brother PE545?

Ans: You can import embroidery designs into the Brother PE545 using a USB memory stick via the built-in USB port. Simply save the embroidery design files (.PES format) onto the USB memory stick and insert it into the machine. Access the USB port menu on the machine, locate your design file, and follow the on-screen instructions to import and stitch the design.

Q2: Can the Brother PE545 sew regular garments and fabrics?

Ans: No, the Brother PE545 is an embroidery-only machine and does not function as a traditional sewing machine. Its primary purpose is for embroidery projects, and it does not have the capability to perform regular sewing tasks such as garment construction or basic stitching.

Q3: How can I avoid thread nesting or bird’s nesting during embroidery?

Ans: Thread nesting can be minimized by ensuring proper thread tension, using high-quality embroidery thread, and securing the fabric tightly in the hoop. Additionally, keeping the machine and bobbin area clean from dust and lint buildup will also help prevent thread nesting issues.

Q4: Is it possible to resize embroidery designs on the Brother PE545?

Ans: The Brother PE545 does not have built-in resizing capabilities for embroidery designs. To resize a design, you will need to use embroidery software on your computer to adjust the design’s size and then import the resized design into the machine via the USB port.

Q5: Can I use third-party embroidery designs with the Brother PE545?

Ans: Yes, you can use third-party embroidery designs with the Brother PE545, as long as they are in a compatible format (.PES). However, ensure that the designs are from reputable sources and meet the size and complexity limitations of the machine to avoid compatibility or stitching issues.


For any problems or troubleshooting related to the Brother PE545 Sewing Machine, users are advised to refer to the machine’s manual for detailed instructions and solutions. If the issue persists or requires further assistance, contacting Brother’s customer service or visiting a certified service center is recommended.

Proper maintenance, adherence to guidelines, and correct usage will ensure a satisfying embroidery experience with the Brother PE545.

Leave a Comment