If you have access to The Quilt Show videos - I just watched part 2 of the Ricky Tims tut on Rhapsody quilts. He shows a way to cut multiple layers of a motif to be appliqued. It looked really interesting (tho I have not tried it). Actually, the whole video (parts 1 and 2) are fascinating, but in particular in video 2 he shows this technique. I am not sure I can explain it, but has to do with fusing the layers (but not fusing solidly) then cutting, then separating the layers.