This case report describes a rare complication of sheath rupture during Figure-of-Eight suturing following catheter ablation. A 44-year-old male undergoing electrophysiological testing experienced sudden sheath rupture upon removal, necessitating emergency surgical retrieval. The mechanism likely involved three factors: accidental needle puncture causing initial damage, excessive suture tension creating structural compromise, and shearing forces during removal precipitating complete rupture. Preventive strategies include maintaining appropriate needle placement away from the sheath, controlling suture tension, and retaining an intraluminal device during suturing for mechanical protection. This case emphasizes the importance of standardized procedural protocols and thorough operator training to enhance patient safety during vascular closure procedures.