I am modifying a model that has a thickened surface. After I
make my shape change, I am no longer able to create a thickened
surface. I get the "Unable to thicken the Surface" error. It shows
me a preview, but does not complete the feature. If i do not add
the surface that has the shape change in the knit, then the surface
is created. Can anyone help please??

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Minimum radius of Curvature: 3.93701e-007 in
Do a Tools, Check on the model, and you see this right at the degenerate point. That's your problem right there.
I hate to sound so crass, but this problem is discussed at length in my book and in some blog entries.
Hi all,
I'm researching about effect of new materials on bumper fascia, I downloaded one CAD file form Grabcad.com, Unfortunately, It's in surface type, and I'm a new guy in Solid Works. I trully need your help. It's always say " Unable to thicken the surface" I try many ways but it didnt work.
Here are my file: https://www.mediafire.com/?b9i5z6xfag1775d ,
Thanks in advance
Roll back in your feature tree just below Surface knit 6, then edit your Surface knit 6 to include the "Surface-loft10" , then roll back down in your feature tree. your part will thicken with thicken22, thicken12 can be deleted. Tom