It’s typical when the border is a different color than the fill when we digitize something, for the border to appear thinner in some areas, and exactly how you intended for it to look in other areas.
This is because when the satin boarder stitches line up the fills stitch direction, the border’s stitches sink into the fill, making the border appear thinner than it is.
When the border’s stitches are more perpendicular to the fill stitches, they bite into the fill and stand out better. This can be corrected by first adding center run underlay, and if this doesn’t correct the problem enough, a double zigzag
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