I have a Bernia deco 330 with a 5x7 and 5x4 hoop and a Brothers Disneywith a 4x4 hoop.
I stitched the same design with all 3 hoops using the iron on stablizer and same fabric.
MY PROBLEM is that the 5x7 outlined very faint and didn't seem to be in the right spots all the time.
5x4 was a little better and the Brothers was GREAT.
Any ideas what is wrong?

If you changed the size of the design, that could be what caused the difference. That would be my assumption.

You may need to calibrate the machine. I've had to do this before. Instructions are in the owner's manual. I have the Bernina 200, it shouldn't need to be taken back to the dealer to calibrate.

They were all the same size. I will try to read my book and see how to calibrate it

I have had this problem too. For me it is the hooping. When the design is stitched out it draws the fabric up just a little bit then the outline is off. Practice on hooping has helped me, even though I'm still not perfect. Go to annthegran.com and look on her blog (at least I think that's where I found good information) and look for hooping. That's a great site for embroidery people. Good luck!

Did you buy the design in both formats? The difference may have happen in the conversion. I assume your Brother uses .pes. What format does Bernina use?

It could also be how fresh is your needle in each machine. The hooping is alot of it along with the design type! It may have been created in one type then converted to the other and in the conversion depending on the software to convert it changed it.