I have a 4GB card that works great. I have a million designs on it.. prolly need to delete some of them out. Sorry I don't know why it is giving you trouble. What do you use to put the files on your card? I use CF Write... I don't know how many different progs. are out there do do this. You may try to uninstall your program and reinstall it then try to transfer the design. It might be that your barudan doesn't "see" the file there because something is corrupt.
by the way, if you use df write... make sure that you dont put any spaces in the name or any funky punctuation.... it won't transfer that way.
Just a thought.