I never have a problem making them this way. The only thing I can figure is maybe it is the way you are pressing them open. You want to press not iron. Ironing them back & forth can distort them. Also, if you are not making all the seams, around the block, a true 1/4 inch may also cause this to happen. I have guide lines on my food that helps me make sure I keep them all true. If you don't have this on yours, maybe you could put tape on your face plate to help you keep all lined up.