Since other brass worked well in the same F/L die it’s the brass thickness of the Starline brass.
Do you think it’s the neck size that’s the problem?
Or shoulder bump not being enough?
Do you have a Match Chamber? Those tend to be tight especially if the gunsmith is on top of his measurements when cutting the chamber.
i.e. I have more than a few chambers in various calibers that even brand new brass will fit like a custom made leather glove. After firing they can even come out smaller! i.e. shoulder length. Or neck chambers that are minimum spec for the various manufacturers of brass and their neck thickness. i.e. ADG, Lapua, Peterson, all have thicker necks than Winchester, or Remington.
Lapua 308 Winchester uses a .335” bushing vs .329 for Winchester brass, Federal is .333” bushing. Just depends on the brass and the cartridge and who makes it or the lot!
Or in some cases it’s the die that is making the case grow in length and/or your chamber specs.
It’s clearly something happening since the fired cases will rechamber fine, but after sizing you run into issues….. Firm to unable to close your bolt down on a resized piece of brass. (which is the cause of the issue). It’s growing in some way.
In the end, most manufacturers will just ask you to send them (10) Ten 2-4x fired pieces of brass from your weapon and they will fix the problem!
Hope that makes sense, and/or helps. BTW I’ve sent in more than a few dies to have that done, so it’s more common than you might think.