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So I've tried printing custom decals for my minis and failed miserably.

I used this Testor's paper and Testors' decal sealer. I printed and sealed the decals with no issues, but during application, they curled in on themselves, no matter what was tried. This isn't the question of the lack of skill as the person who tried to apply them is quite good at it. His supposition was that this decal paper is badly suited for small decals. So I'm inclined to blame the paper.

Can anyone suggest a better paper for small custom decals? (I'm printing badges to go on SM shoulder pads). It has to work for inkjet printers and be opaque as the decals will be going on a black background.

I use a wet pallette to moisten decals. Try putting the decal flat on a wet sponge or something rather than immersing it, and teasing it flat as it curls.

Tried that, still no go.

I had a similar problems with these. I ended up applying Microsol (or rather, Mr. Mark Softer, a locally-available equivalent) and smoothing the edges down manually with an old brush. It was a little time consuming, but it worked.

I have never had an issue with Testor's but give a different brand a try.

I use the papers from Micromark

https://www.micromark.com/INKJET-DECAL-TRY-IT-PACK

They have a wide selection and I believe still sell a starter kit with softening and setting solution plus fixative. I used the basic kit for many different sets and types of marine decals. They worked perfectly.

You might already being doing this, but for small decals cut through the decal paper over an area much larger area than the decal itself. Then cut through the decal close to the decal, but don't try and cut all the way through paper, just cut lightly, far enough to go through the film.

And use a really sharp knife while doing it so the decal actually gets cut rather than torn (just use a brand new blade).

Cutting decals out that way puts minimal stress in to the decal itself and the scrap bit of film should fall away easy enough when the decal is wetted out.

Maybe change how you apply the decals?

I've used microsol and microset with pretty good results.
They can be a little labor intensive, and you've gotta religiously follow the instructions. However, the end result is always very nice if you're patient and just keep applying thin layers of microsol every couple of minutes.

When I've not had access to those, I've used the GW method of applying over a layer of 'ardcoat, then putting lhamaean medium over the top, and to be fair, it works fine.

I use these often with few problems, you must keep it on the paper, get the edge close to the surface you’re applying to. The use a knife or tool to hold the decal in place while you pull the paper out from under it.

Ended up ordering some sheets from Decalpaper.com... didn't have the "fold on itself" problem during the test phase thank goodness.

Real attempt coming soon...

I've used Testors decal paper in the past to make nameplate decals for models with no issue, might have been a bad batch of paper or a bad batch of sealer (I've always used a regular gloss varnish instead of a special sealer). I usually get sheets of generic decal paper off Ebay now since the Testors stuff is a wierd half-sheet size, also with no issues