....using appliqué stitch? Hand or machine, turn under, blanket, raw edge? Maybe the fusible was "old" or not ironed on right...many variables......
But in thinking this out....one washes the fabric to remove sizing chems, then sprays on starch....wouldn't that be the reason the fusible doesn't stick? Doesn't the directions advise washing fab to remove sizing so that fusible will stick..it seems the starch has added another barrier to the " stick" factor.....