Has your .NET COM interface changed? If so, you will need to re-regasm your .NET dll in order to update the COM registry accordingly.
Also, if you update the version of the .NET dll with new builds, you'll want to make sure you don't have conflicting versions registered. Try searching the registry for the name of your dll and deleting any keys under HKCR. Then try re-regasm'ing your .NET dll.
Finally, I've seen this error when a constructor (or static constructor) in .NET throws an exception during the creation of your .NET object. Add some tracing and error handling to make sure this isn't the case.