Attached is a zip file of a dataset I created. Have a look at TEST_PART_SOLID.ipt first to see how I created the negative of the shape I wanted (you could use a positive also-depends on your needs). Then look at TEST_PART.ipt to see how I used the DERIVE and then THICKEN tools to create the sheetmetal part. You will need to review the earlier video about derive and thicken. I don't know why you are having trouble. I see that the Cut1 produced dodgy flat pattern results. This is why you should either
Best of luck.
Thank you Brendan. I have now understood the concept. The geometry is now perpendicular to the sheet. Unfortunately, my CAM software (RADAN), still does not auto tool the produced geometry. The circle and hex do not produce a smooth curve or lines. I might need to ask CAM guys for support.
Thank you for your assistance.