I think the 'dust' is like a powder to prevent sticking.

I don't know much about badgemaster. I use 2 layers of Vilene (the fabric type watersoluble) Hope this helps.

I use one layer of Vilene unless I want my design to be *very* stiff. Then I make two layers and stuff all of the scraps in between like a sandwich. Experiment and see what works for you. If you've been using a lot, try playing to see if you can get by on less. That would definitely cost effective. Good luck!!