I think you may need a needle with a larger eye, loosen the tension a tad.
Are you using Quilting Needles?
If you are able to sew a few stitches before it hits the sole plate. It sounds like it would be the pressure you are putting on the free motion.
If the thread can't get through the eye as fast as you are moving, it will pull the thread tight and you will bend the needle just enough to hit the plate.
Keep trying
Syl