I have had similar issues and have adjusted bobbin & hook assembly, move approx 1/32-3/64 to the right, what was happening was the pressure from welt[or offset thickness of materials being sewn] have been bending/pushing needle causing tip of hook to catch. Now of course. I am having a drop-stitch issue on other thicknesses such as heavy plastic extrusions, but not as critically, and have not finished my fine-tune as this adjustment just took place this week. But I did alleviate the issue at hand and it has allowed me to sew the "important" seams without issue. For every action, an equal to or greater reaction.
I could actually hand walk the needle foot downward and watch the needle bend to right and just catch hook tip.
Be very careful not to mess your timing up up when doing so.
I also believe the cheaper grade metal used in the needles has attributed to the needle bend. Needle thickness can also vary the amount of bend but I personally cannot use the thickest available on a lot of the stitchwork I do.
Dave