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Haven't got IV11 installed (used IV11 Viewer to look at the part), but have
you tried selecting the Face that you want FlatPatterned before pressing the
FlatPattern button? Delete the existing FlatPattern first. Also do the
thicknesses match between your model and sheet metal parameters?
Please see the attached part. This is what I did to it:
-Delete the extrusion, keeping the sketch.
-Delete the fix constraints and removed one of the offset sides in the
sketch.
-Add tangent constraint on arcs and lines then re-add the fix constraints.
-Create contour flange.
-Create flat pattern.
![Autodesk Design & Make Report](https://forums.autodesk.com/t5/image/serverpage/image-id/1350519iCB55845EBFC43016/image-size/large?v=v2&px=999" "Autodesk Design & Make Report")