My foot does this with different thickness of fabrics, it will make the foot land in different, areas, sometimes making the needle hit the foot. Always check needle position before you start embroidering. once your hoop is ready, check the clearance. I often have to use a small roll of non slip material under the foot handle, the one used to bring the foot down. And I use this to adjust the needle postition so it will always land in the middle of the embroidery foot. There is also a way to adjust the height of the needle arm but that's too complicated to get into here and I've never personally tried it.
Sounds like your tension is too tight and the thread is pulling your needle. Also, make your that you needle position button is on center. If it is on left or right it will cause your needle to snap.
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