This was my line of thinking also, although I'm not familiar with this brand. Try a poly thread.

MarionsQuilts I have a Dreamweaver 6200d, approximately 5 years, and have the same exact problem ! I recently had the machine serviced and the tech could not recreate the problem - probably because he cleaned the machine first. I also use Threadart, a local business which I support, but have not noticed a difference with other threads. Following your posts.

I have an older Brother with the bobbin sensor and, if anything, it is too sensitive. It has never been a problem and I use Thread Art thread all the time.

I emailed brother support again - the same person I dealt with last time. Will see what happens.

If you find a solution that works please post about it. It helps a lot when others need help with a problem machine.

Its probably your thread. I have had my dreamweaver for 8 years and never had a sensor issue

I have an older Bernina 1630 and have the same issue with the bobbin sensor. Sometimes it works and sometimes not - I think it is probably caused by the differnert types of threads that I use. I know that the sensor is a terrific tool - If it doesn't work I try cleaning up the bobbin area and if it comes on great if not I am afraid that if I poke around too much that things may go out of wack - I love working on this machine and because it is older I try to be cautious and hope for the best - really don't want to mess anything up with her so that I can continue to enjoy her.

My friends with the bobbin sensor issues in the Brother Dream machines all said the tech told them to use better quality thread.The new machines have such good technology in them that any slight imperfection triggers the sensors. He said sensors are all made by one manufacturer and sensor are made to sense any thing not up to specs. He can change out a bad sensor but if the imperfection is still detected it will cause the same problems. This is how they explained how the tech explained to them. So maybe not as detailed as he said it.

Is your machine working better for you?

I've had the VQ 3000 for about six years and I find I have to clean frequently and thoroughly to have the bobbin sensor work. I've never had the sensor replaced.

In fact, other than routine servicing, the only thing I've had go bad in the six years is the electronic needle threader, which was replaced three years ago for about $12. The newer one just died, and unfortunately I'm going to have to drive about 90 minutes to the dealer here (we moved since I bought the machine.) There are videos online on how to do it, and I know it's only a five minute job, but I'd rather have someone who knows what they're doing replace it for me.

Other than that the VQ3000 Dreamweaver has been great!