I have found the same thing. I press to the dark side, but when I assemble...all the dark sides are not going the same way so the connecting seams aren't either or they bunch at the junction. I haven't found a solution for that either. I have been tending to press toward the heavier side...cotton/poly is thinner than 100% cotton and I just press to the side it shows through the least. I have also found better to press toward a print than the solid.