I always sew mine on my machine. I haven't had any trouble. A couple of things you might check:
Is the needle old? That will cause all kinds of trouble.
Check to see that it isn't for light fabrics, also.
How about your tension - is it set for medium or heavy weight fabric?

I hope this helps you. If these don't help, I have no clue what might. Good luck.

I sew mine on the machine, even have a foot made for hook and loop closures. Its bottom surface is higher on one side so it sits nicely on the h & l.

Are you using "sew on" velcro and not the kind with adhesive? The first time I sewed velcro I did it with the kind with adhesive. It was difficult. The needle would get stuck in the adhesive and I think I broke one needle before I realized what the problem was.
With the correct kind - no problems.

Thanks all. I was trying to sew through stick on dots of Velcro...back to the store!

Suzi

You can buy a product made by Dritz that makes sewing through sticky Velcro a breeze. I once bought some knit fabric that had shinny dots on it and it gummed up my needle after about 2 inches of sewing. I bought this stuff and put tiny drops on the machine needle and it sewed without problems. I can't remember the name but it comes in a bottle that looks just like fray check. Ask your clerk in the fabric store.

Sewnice, you might be thinking of either Needle Lube or Lube A Thread.

I sewed strips of sew-on (not adhesive) velcro and it was a breeze. I have a 20-year-old White "Jeans Machine" with a denim needle that came with it. I think all the settings were normal, I don't think I adjusted the presser foot or tension.

I do recommend a good strong, sharp needle for this though.

And definitely the NON-adhesive velcro.

Jen

I always sew velcro on by machine,but never use the adhesive stuff.The regular sews on in a breeze for me,no problems whatsoever.In Fact i sewed a bunch on last night as i was making wallets.Besides that adhesive stuff doesn't hold up worth a hoot!!
Kathi

keepem: tell me more about the velcro foot. great idea !!

It's a #38 Bernina foot and can also be used for piping. It is be used with a straight stitch in the center needle position only. It's a bi-level foot...when you look at it from the botton with the presser foot shaft away from you, the right side of the presser foot is higher than the other. "This allows it to ride smoothly over an uneven surface, avoiding imperfect stitches that might result from using a foot that is unsteady." ("Bernina Feetures" book, Vol.2, Unit G, page 7.) Only the left portion of the foot comes in contact with the feed dogs. "Fabrics and trims are placed under the foot and aligned with the left side of the sole, which positions the edge of the thick layer directly under the needle. The "wall" formed by the left side of the sole creates a guide for precise straight stitching along the edges of trims such as piping, cording, braid, and bulky tapes." (ibid). Other uses are for constructing welt pockets and flat felled seams [although Bernina has other feet for the latter, #70 (4mm) and #71 (8mm)].

The velcro foot works well, but it takes a little getting used to, having the thicker fabric on the right side of the foot when it's in the machine.

Hope this explains it. (The book says it better than I could've!)