Nathan – I assume the longer stitch length for lighter fabrics is due to the risk of needle holes too close together compromising the fabric’s integrity at the seam? Some sewers advise shorter stitch lengths for added strength in key areas of a job. But that advice would only hold true if the fabric is substantial enough to support closer, denser needle holes. Would it be correct to say that every fabric has a unique optimal stitch length (for a given thread and needle size) that balances the competing factors of longer lengths punching fewer holes versus shorter lengths providing more support from the tread?
Yes, this. Problem is with thinner/lighter fabrics, stitch hold elongation becomes an issue at some seams that can lead to tears along the seam itself. Longer stitch length allows a material to spread forces over larger surface area of material between stitches.
As an example, I’ve seen tightly bartacked tieouts on silnylon tarps tear out, wheres I havent seen box and cross stitched tieouts fail in the same way. YMMV
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