sounds to me like a heavey wetter ? some nappies arent just absorbent enough for big wee'ers .

fwiw my DD is not a big wetter but has leaks in a bubble bubs too . so i dont use them anymore .

cushie tushies IMO are not really absorbent and arent the best fit on my DD so maybe the fit isnt right ?

the BBH and ECO bubs are both predominatley microfibre . i think its sounds like its not absorbent enough .

seeing as you are getting good results from a cushie (is that the fitted bamboo?) and a cover , maybe fitteds are the way to go for you ?

my DS was a fitteds boy - he out wet AIO's and was sopping in no time , i stuck him in a BBH and cover and its was fine

try doing a stip wash them whack them in the dryer , maybe the PUL is not preforming at its best and there may be some build up , even if they are newish ...

dont listen to DH and the "i told you so's " its a steep learning curve and it takes a while to master whats right for bub and you !