In order to get more trims from an Expanded design the Jumps Stitches for Trim setting should be lowered. The default is 2 jumps to make the machine trim. Changing it to 1 jump for trim will make the machine trim more often. That setting is found under Tools>Options in DesignShop. Note that after changing the value the design must be reloaded for the change to take effect. This should be done in both DS and OS. In OS it is in the Advanced Interface under Tools>Settings.
This will not work on areas in the design where there is only a long stitch connecting two areas. It must contain at least one jump. This happens when the digitizer who created the Expanded design doesn’t have the correct trim output settings set up within their digitizing software.