Specific dimensions and framerates are relevant for both what went wrong with this project and what will go wrong with future projects.

Standard def signals look like crap on high def TVs because the conversion is asymmetrical.
480→720→1080
A 1:1 conversion from flash to DVD format will yield much better results than a .637:1 conversion.

What resolution is the final product going to be viewed at?
Matching that resolution will give the best results.