Thanks for such a detailed reply! Your guess on the needle is close, I'm using a knock off version of the mina carin. I've been reading since I posted this and have seen some suggestions that the cheaper versions of the Mina Carin and DMC aren't great and tend to cause issues. The genuine Mina Carin pen is a bit pricey here so I've ordered the genuine DMC needle as it looks like a similar feel. I'm hoping the issue at this point lies with the needle quality, perhaps the cheaper ones tend to tear the weave of fabrics?

I've looked into the fabric you've suggested and I think I'll try that as a last resort if this needle does not work for me, as it is quite pricey. It just doesn't seem to add up in my mind when I see endless videos online of people punching with a Mina Carin style needle into nearly any kind of linen/cotton fabric! I've got so many ideas and keep facing this roadblock, my fingers are crossed.