Modeling folding surfaces with nonzero thickness is of practical interest for mechanical engineering. There are many existing approaches that account for material thickness in folding applications. We propose a new systematic and broadly applicable algorithm to transform certain flat-foldable crease patterns into new crease patterns with similar folded structure but with a facet-separated folded state. We provide conditions on input crease patterns for the algorithm to produce a thickened crease pattern avoiding local self-intersection, and provide bounds for the maximum thickness that the algorithm can produce for a given input. We demonstrate these results in parameterized numerical simulations and physical models.

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