Just to check the dumbest possibility, but you are baking these things at the right temperature and time? Including allowing more time for the thicker items? I don't work a lot in polymer but I played around to understand it and made a small pinch bowl with about 1/4" (6mm) thick sides and bottom and baked it by the rules - it is so tough that I can drop it several feet to the floor or other hard surface without visible damage.
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