I tend to use a no 28 for almost everything. It is just what I prefer. I will use a no 26 in a pin ...
Same here. I find that within a pack of DMC #28, there are slight variations in each needle, some are finer than the others. I use the one I am most comfortable with, and keep the finer ones for backstitching - the hole is finer too, so it accommodates 1 thread quite nicely without cutting the thread.
Agree with VampKira that the finer needles go through smoothly. For me its important that it does not pierce the leg of the next stitch, slicing the floss. A lot of sliced stitch show up on the finished work, giving it an unruly appearance- maybe because of the uneveness, and therefore affecting the way light is reflected . . .
I feel that its more important that the needle hole accommodates the number of thread comfortably :)
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I find that sometimes a smaller needle (26 or 28) in very tight fabric will cause the floss to shred, because of the extra friction, and if that happens, I will go to a larger needle to prevent that. Also, with metallic thread I always use at least a 24 no matter the fabric because the metallic thread twists and tangles so easily.