Karen, Do you have software for your embroidery unit? This sounds like you need to reduce the stitch density. Even if you don't have software, join groups.yahoo.com/berninav6software. when your membership is accepted (everyone gets in unless you are wacko, and probably even then
), do a search for "density" and you'll be able to see the discussions about this.
To fix density, you may need to increase the spacing between stitches. Unfortunately, many OESD designs are very dense, beautiful, but dense & it helps to know how to adjust them.
Hope this helps
Susan