Creating a Sheetmetal Flange Error

[colinNJB25]

I am making a complex hopper. I would really like the flange tool to allow me to set the angles of the sides. Since I can't I have had to cut the sheet metal to shape with extrusions. I have a part that will create a flat pattern but one side will not allow me to create a flange. This is a spot welded flange.

The error I am getting is "Can't complete Sheet Metal operation due to an internal error. Check the body and bend parameters, then try again." I have tried offsetting the ends away from the other surfaces and only bending 45 degrees so the body does not interfere. 

Does anyone know a work around?

[TheCADWhisperer]

Model the design as best you can using standard tools (no sheet metal) and then Attach your attempt here.

[colinNJB25]

Thank you @TheCADWhisperer, I would really love to see how you would do this. I have to get this print out to the shop in a few minutes so I don't have to to remodel it. Its clear the software can't quite sort out what to do at the ends of the bend. I even tried to put a 1" long bend in the middle to see if it would try and had no luck.

I struggled through it. I had to make some notches on that face and then make a hand calculated bend line. It made those intersections pretty messy and I had to clean them up with extrusion cuts the best I could. Extruding around the sheet metal bends has never really worked out for me. I think it is pretty decent and I was able to get all of my angles from it. It is odd that when I clean up that mess on the flat pattern it doesn't carry out in the model.

[TheCADWhisperer]

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@colinNJB25 wrote:

 It is odd that when I clean up that mess on the flat pattern it doesn't carry out in the model.

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Unfold (not Flat Pattern), clean up and Refold- THEN Flat Pattern.