I've run into a similar issue before, but I don't have any solution for it. I quickly made a surface body to test some ideas on this issue, but I was unable to figure anything concrete out. If you could describe your surface part, then I might be able to help you figure it out. When I did run into something in my quick test, it appeared that one of the surface portions had folded over on itself in a few locations which made the thicken command fail. Aside from that, I don't have much to tell you.