I have to say it really looks like a bobbin issue to me too. A great place to get embroidery help is at sew forum.com. I have a Brother Innovis and have found it to be a most reliable machine. If you can, take the machine back to the dealer and ask them to watch you thread the machine and put the bobbin in as well as do a design. Another suggestion would be to do some designs at home and as soon as the problem starts, stop the machine and take it to the dealer. It may be awkward but if you can finish the design maybe then the dealer can see it in action.