Kirk
I also have the same problem in Inventor, Inventor as good as it is at creating the sheet metal shapes, the unfolder is just not up to doing some of the more complex things, that is why I use AutoPOL, the same goes dor SolidWorks and SolidEdge, their unfolders are not that good and really only suitable for regular bend sheet metal, try asking any of these packages to unfold a straight variable fillet bend (lofted) say from 2mm to 10mm along a length, none of the above can do this (SW has a variable command but it will only unfold parts created with that command). Try downloading the FREE eval version of AutoPOL and see what you think, it also unfolds "LIVE" Inventor models, so while you have IV open you can open that file in AutoPOL with the Inventor Exchange (no translation required), the results are perfect. As you can tell I have been a fan of AutoPOL for many years and used it in earlier versions of AutoCad to give me full SM capabilities. By the way the eval version needs no keys or codes, it just works, the problem is you canot save. I think AutoPOL should be used as a sheet metal production tool as that is where it seems to fit best, and it unfolds models from any other system as well.
regards
Bill