I had the same thing happen with an XD-45 Service model a few years back. Slide was stuck shut on a live round, would not fire, and it was a herculean effort to get it open, took about 20 minutes. Inspection of the subject round showed no obvious issues such as a backed-out primer or other. Sent it back to SA, and they replaced the ejector (not sure if this was the cause or the result of the failure). The only thing I could figure at the time was that I was shooting some reloads where I had experimented with slightly different COALs. One of the longest of those, which was 1.245", was the round that caused the failure. This is well below the max length specified in most reloading manuals (1.275"), and I was using a calibrated and verified Mitutoyo caliper, so my measurements were not suspect. Went back to shooting only 1.2" COAL loads and never saw that happen again. The longer loads fed with no issues in a Glock 21, Colt 1911, and Taurus PT145, but for some reason the XD could not, would not, digest them. Not saying this is your exact problem, but suspiciously similar.