hmm you know ive often thought about doing that, it seems in theory at least that the modular peices don't line up that well in relation to becoming a flat square in the unfolded end.
so it would be like, fold one modular peice...find its cp, then see how the modulars fit together and create a larger cp incorporating the correct number of modules in a somewhat appropriate way conneting them all somehow.
the idea is very valid..i just dont comprehend how to implement it
"The most profound statements are the ones that never get said"
Interesting thread, the reason modular are good for polyhedra, stella octa, and 3d fracturals is the fact that they are sturdy, the indiv. pieces hold together well,
Other than the link you provided I am not sure of another way to do this in a way that will result in a clean sturdy model.
In using sonobe modules if you use the traditional sonobe variant it will hold together better and more cleanly on the flat surface.
the picture you put in your op usues and different Sonobe variant, looks like an extra fold on the flap make the flap with one less fold it will be wider and will provide thinner module which will assemble flatter.