We are having issues where we email an estimate it does not look our customized form, the erroneous ones look more like a "register tape" no formatting whatever

Let’s ensure to use the correct template of your estimate, @usersebandor-imw.

It could be you’ve selected the wrong template, thus, it’s showing the wrong format. Let me show you how:

1. Go to the Gear icon.
2. Click Custom form style.
3. Locate your preferred estimate form template.
4. Click the Drop-down menu beside the Edit link from the Action column and select Make default. 

Then, email a sample estimate to your own email address to double-check. If the issue persists, I suggest deleting and recreating your estimate template to isolate this issue. You can refer to this article for additional guidance about the process: Customize invoices, estimates, and sales receipts in QuickBooks Online.

Once everything looks good and your customer accepts your estimate, you can now easily convert it into an invoice.

In case you need to add different designs to your invoice, you might want to import your own form style.

Let me know if there’s anything you need assistance in sending an email estimate, I’ll be around to help and back you up. Take care and keep safe.