Unable to create flat pattern

[matthewgreig]

I can't get Inventor to create a flat pattern of the attached sheetmetal part. It's a pretty basic part, just five folds. I'm not getting any error issues - when I go to the flat pattern it just shows the folded part (picture attached). 

I assume it has something to do with the way I folded it and the notches, etc. Inv makes to accomplish the fold. But I'm very much an amateur - how do I troubleshoot this?

Thanks,

Matthew

edit: I'm using Inventor 2013 on Win 8. 

[jletcher]

I can't open your part but I do believe your issue is with this area. your cut goes into te radius of the bend. can you edit the sketch for the leg fold cut out so I can see it.

[coreyparks · Accepted solution]

It has something to do with how the folds all come together in the middle I think.  I have had problems with the fold feature creating things that couldn't flat pattern so I rarely use them.  I rebuilt the part using other methods and it flat patterns fine now.  I wouldn't have used the fold feature but I didnt want to redo the entire part.  Take a look and see if this method will work for you.

[matthewgreig]

James, not sure what you mean by the leg fold cut out sketch, but you guys are right that it's the folds. Corey's redo using a series of flanges for the "wings" allows it to flat out just fine.

Thanks for the tips - I'll avoid the fold feature when I'm doing close tolerance stuff from now on.