topic Re: Flat Pattern is not Flat in Fusion Design, Validate & Document Forum

Flat Pattern is not Flat

trevorthiessen — Mon, 10 May 2021 14:07:58 GMT

Hi,

here is the file that I mentioned in the comments section of the "Caution on Source of Information A Sheet Metal Pyramid in Fusion 360" youtube video.

I can create a flat pattern, but the sheet metal does not unfold in the flat pattern. Can you help?

hanks

Re: Flat Pattern is not Flat

TheCADWhisperer — Mon, 10 May 2021 21:55:23 GMT

Are your sketches fully defined?

Are there any unresolved issues highlighted in your Timeline?

Does Ctrl B (CMD B on Mac) return any errors?

Re: Flat Pattern is not Flat

trevorthiessen — Mon, 10 May 2021 23:11:25 GMT

There are numerous errors on CTRL+B, I guess I'll need to start again from scratch. I suppose that's all part of the learning curve. Hopefully, this gets a little easier as the software continues to be developed.

Re: Flat Pattern is not Flat

TheCADWhisperer — Tue, 11 May 2021 11:46:37 GMT

@trevorthiessen wrote:
I guess I'll need to start again from scratch.

You came to the best conclusion.

Forget all of the other geometry.

Concentrate on this sheet metal part.

But Attach your file here after completing Sketch1 for diagnosis and suggestions. Otherwise you are likely to create a file that nobody will be willing to diagnose.

Step-by-step is the way to go.

Never leave unresolved issues.

Re: Flat Pattern is not Flat

trevorthiessen — Tue, 11 May 2021 12:33:03 GMT

Thanks

Re: Flat Pattern is not Flat

trevorthiessen — Tue, 11 May 2021 20:03:05 GMT

Ok, I have redone the part.

All sketches show fully defined. I do not see any unresolved issues on CTR + B.

The flat pattern still isn't working. I have attached the updated file. Is it easier to diagnose now? I'm guessing there's a problem with the fillet bend? I tried leaving the fillet on the same size for the top and bottom sketch and I have also tried using a sketch fillet that's based on the ratio of the circle on the sketch. I was also thinking of adding the fillet after extruding the part when it is still a solid, but due to the nature of the cone, it seemed to be causing other problems.

Re: Flat Pattern is not Flat

TheCADWhisperer — Wed, 12 May 2021 12:25:56 GMT

@trevorthiessen wrote:
All sketches show fully defined.

Can Sketch1 be dragged anywhere on the screen?

Re: Flat Pattern is not Flat

trevorthiessen — Wed, 12 May 2021 14:02:46 GMT

Yes, I was able to drag it around. I have locked it now.

This is the error I see on the flat pattern:
"Error: FlatPatternAlign1(FlatPattern1)
Compute Failed
Failed to identify sheet metal faced for some edges. Ensure the body is a valid sheet metal body that keeps opposite faces separate."

Re: Flat Pattern is not Flat

TheCADWhisperer — Wed, 12 May 2021 14:07:47 GMT

I don't think Fusion 360 is ready for professional use.

I moved on to other work.

Re: Flat Pattern is not Flat

Phil.E — Wed, 12 May 2021 15:23:50 GMT

Thanks for the design. There is a bug report for this now, and an improvement ticket to add lofted flange.

Re: Flat Pattern is not Flat

rwithrow7XLCS — Mon, 01 Jul 2024 16:59:59 GMT

i have ran into this same issue 3 years later. is there a solution to this problem yet? my flat pattern works fine until i add a fillet to the design then i receive error code "flatpatternalign1(flatpattern1)"

Re: Flat Pattern is not Flat

Phil.E — Mon, 01 Jul 2024 17:01:07 GMT

Can you share the design file, images, or a video of this?

Re: Flat Pattern is not Flat

rwithrow7XLCS — Mon, 01 Jul 2024 17:30:40 GMT

in the attached file you'll see that the flat pattern doesn't unbend properly until you either remove the fillet entirely or edit the timeline to show the fillet isn't yet present in the design.

Re: Flat Pattern is not Flat

Phil.E — Mon, 01 Jul 2024 18:34:53 GMT

Actually if you add a smaller fillet value, you'll see why. It works up to R 0.15"

You are asking Fusion to bend two flanges so that their bending zone overlaps. Do you have a picture of this part after being bent by a press brake, I would like to see how a press brake handles that corner.

Also notice that the compound nature of the fillet produces a flat that cannot be made with a laser or punch. That fillet, in the flat, is not a regular cylinder.

IMO, this is a case where that corner feature could be reconsidered. The most important thing to know is how the flat goes from your desired design to a bent part. This can easily be achieved by exporting a flat pattern and adding the 0.25" fillet in the flat pattern, then try to bend the part on a press brake. Have you tried that yet?

Re: Flat Pattern is not Flat

rwithrow7XLCS — Mon, 01 Jul 2024 18:49:35 GMT

I do not have the actual part but I do have the drawing. I'm being asked for a flat pattern drawing for a quote on outsourcing laser cut and bending of the final piece.

Re: Flat Pattern is not Flat

Phil.E — Mon, 01 Jul 2024 19:48:57 GMT

Thanks for the diagram.

There isn't much to go on here, but this raises a question for me:

I've seen designs that existed on paper that cannot be made in CAD. I'm not saying that's what is going on here, but the original drawing appearing to not match a CAD model with the same size callouts draws my attention.

A photograph of a physical sample showing the fillet that is causing problems would be super helpful. I want to see what it looks like bent. This might be a limitation of Fusion flat pattern generation. If it is, I want to log an improvement ticket.