Yes, I have experienced this, and you probably won't like my answer. I switched applique methods. I no longer satin stitch. Most of the time I turn under and hand stitch, using the freezer-paper-and-starch method of turning under. If I DO machine stitch the applique, I use a button hole stitch. You can use fusible, but in my experience the fusible doesn't always stay fused after washings.
eta: it occurred to me that you could use a firm stabilizer on the back of the fabric, but you'd end up with stiff appliques, unless you cut out the centers after stitching. In my opinion though, it would be easier to hand stitch, or machine button hole stitch.
Last edited by Peckish; 10-24-2012 at 08:05 AM.