If it used to work out to 1/4" it may be a little bent in at the toe. Mine got bent out a little from trying to open the bobbin hatch when the foot was down. I have been unable to bend it back so I nudge the needle over one blip.
Or it may be new thread/material combo or intricacy of the pattern? You will have to do the cut-3-pieces 1 1/2" x 5" and sew them together side by side with what you think is 1/4" seam, press, and measure until it comes out right. tiresome, but it works every time!
