I've had that problem when the stitching causes the stabilizer to pull and shift just enough that the end stitches don't quite hit the right target. I've never used metallic thread, but have had your problem.
I hadn't closed the page after writing a comment, so thought I would add a little bit. I've done the following before, which is why I ask; not because of anything you have done. I was just wondering if you know for sure that the design was FSL? Some look like they would be, but end up not being, but are close. I hope I haven't offended. Just trying to think of things that it could be. I hope your 2nd stitch-out turned out perfect. Good luck!!
I often use metalic thread in areas of FSL with a regular embroidery thread of the same or similar color in the bobbin. I also alway use 2 layers of WSS mesh. If you did the same, it sounds like either a digitizing problem or a problem converting the design. I almost always have FSL converted from .pes to .jef convert badly.
I used the 2 layers of mesh WSS and matching thread in bobbin. I don't have the ability to convert. I have to use ART3. Thanks for your input.
I don't know about the metallic thread. I've always had trouble with it and have never used it in FSL. FSL has to be digitized well. What design did you use and where did you get it? If we know that we might be able to help you more. Stabilizer is important too.
I used 2 pieces of Aqua Mesh and the same
thread in bobbin as I was sewing with. It was a free design I picked up last week and it was a set of 8 but 2 of designs didn't come thru. It came from www.a designinstitches.com. I'll try another and use just regular embroidery thread.
Thanks for your input.