It's a shame I can't post video on here, as I filmed the trigger in action showing where I think it is catching.
When you back the first stage set screw out, it progressively increases the travel of the first stage but it also pushes the trigger link forward (that's how it increases the travel). If you back the screw out far enough, the link then starts to contact the catch sear.

In the above photo you can see where the catch is touching the link. Pushing the catch up and down with a screwdriver causes it to drag across the link with an audible scraping sound.
I tried to get it to stay in place, but the return spring was strong enough to overcome the friction.
However . . . if some debris were to fall between the catch and the link, it is quite possible it would prevent the catch from returning to its full upward position. A weak return spring would also prevent the catch from returning, but in my case the spring appears to have a decent amount of return pressure.
There are two things about this scenario that have me focussing on it:
1. If you pull the trigger, it releases the catch (which "pings" back into place).
2. If you engage the safety, it also pushes the catch up and releases it.
^ These are both symptoms that everyone who has reported this issue seem to have in common: pulling the trigger and engaging the safety both release the catch sear.
This also explains why the problem appears to happen when the trigger is set up as a two-stage trigger, and why it does not happen when it is set up as a single-stage trigger, as that increases the clearance between the link and catch sears. In my case, it happened when I increased the first stage travel.
I have looked everywhere at this trigger and at the firing pin and bolt with magnifying glasses and a torch and I can't for the life of me see (or feel) anywhere else that might be binding or slipping, so I am still not 100% sure of the cause.
I haven't been able to replicate the issue.