1.I have developed an idea which works well in folded paper, but doesn’t work at all well in my preferred material of chiffon/hinged plywood/polypropylene. What should I do?
Adapting ideas that are successful in folded paper into other materials is always the most challenging part of the design process. The answer is to work more with the material you wish to use at an early stage, rather than coming to it only at the end of a lengthy process of working with paper. By doing so, you will come to know your chosen material better and find workable design solutions. You might even consider not working with paper at all. Learn what your material is good at and work with, not against, those characteristics.
Some materials may not fold well, or ...