One time this happened to me and what my problem was I had put the hoop together in the wrong. The hoop has half arrows that are supposed to be lined up and I had switched them. I also have Ult2003. It is thankfully still running. I hope you figure it out and update us. thanks!
Thanks everyone. I do plan on taking the stitch outs with me (actually I did that the first visit on another design before the servicing but clearly a good cleaning was not the issue). I actually took a photo of a snag with double top threads being brought up which I plan to show them. I've done some researching and wonder if a burr on the needle plate is doing this. I do have a nick I can see but haven't the right tools to address it. Unfortunately needle plates for these old ults are not readily available but hopefully mine can be smoothed out and this is the problem.
Try and do a stitchout of this same design before you leave the store to see if it is actually fixed. Or, maybe make a "sandwich" of fabric, batting, stabilizer to give them to check the stitchout before you even get to the store.
Thanks for reposting and your getting some great answers. I live about 3 hours each way from my dealer/repair source but in lockdown last year my machine visited him via courier. Would this be a possibility for you? I have seen others here before suggesting that you do a stitch out in the shop too. A reliable dealer is so important to giving us peace of mind and a smooth running machine
Am I not understanding the question...are you using batting behind design instead of stabilizer? I have your same machine..there is no problem with batting between cloth, or with stabilizer behind batting. But the tension disk may very well be causingbthebad stitching.
My sandwich is fabric ,batting and then stabilizer. I quess I will be taking the machine back in. When they did a post cleaning sample run they used simple lettering not a big design and this problem, as you can see only occurs randomly. The embroidery arm also is making a rumbling noise when is shifts position which I think is new-(this machine is my spare and hasn't been used since last summer). This shop s a Bernina/Husgvana dealer but they say they do all makes. Unfortunately there is no authorize Brother dealer here.
I use Vies, over it the wadding and then the fabric, never had any difficulties, for appliqué the embroidery foot has to be lifted slightly. Maybe the thread tension of your bobbin case is not correct.
Return the machine to the place of service. They need to check their work.
I agree, For sure!! Remember to take this design stitch out in with you so they can see what is wrong.