The symptoms sound like bird nesting or thread nesting. Although there could be several reasons, In my experience, it occurs most often because the top thread is misthreaded or not firmly seated in the tension disk.
Remove the top thread from the machine.
Be sure you are using a brand new needle.
ALWAYS RAISE the presser foot and rethread the top thread from the beginning. Confirm the thread path is correct.
Now, retest your machine. It also helps to make sure the needle (or the take-up lever) is in its highest position BEFORE taking the first stitch. In addition, pulling the bobbin thread to the top of the fabric BEFORE taking the first stitch is a good habit to use.
Birds nest under the fabric big loops of thread top side looks good...
What causes Bird Nests Superior Threads
Sewing Machine Thread Bunching Up Here Why
Ensure that the needle is installed correctly. If the needle moves down in the needle socket (only a little bit) it causes these clumps. Loosen the needle securing screw - push the needle up as far as it will go and tighten the screw again. Try again.
SOURCE: bobbin tension
This is an issue of your upper thread tension, so take a look at this generic tension solution
If you are in a pickle with your bobbin case, check top tension and bobbin case are free of lint, reset the top tension to 4, and adjust the bobbin tension to suit......some more detail on how to do that, is here
Bargain Box
SOURCE: Thread is bunching underneath fabric
Needle in correct? Be sure your bobbin is not in upside down and turning the wrong way. Possibly the hook that the bobbicase fits in/on has been hit by a needle and caused a burr that is catching the thread as it comes around. The burr would have to be polished off or hook replaced. The machine could be slightly out of time also.
SOURCE: Excess bobbin thread under the fabric
I know you hate to hear this but you are probably threading it incorrectly. Make sure that the presser foot is in the up position when you thread the machine. This ensures that the tension discs are open and the thread makes it in between the disc.
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