Only generating flat patterns from half the parts

[terry_fusion]

I've created (trying to create) sheet metal parts from a solid body but only half the resulting parts will flatten.

From my main original main solid

1. I've copied the original solid into a new component

2. Scaled the copied solid to size

3. Offset the desired thickness for the resulting sheet metal thickness.

4. Generated the surfaces from the solid body

5. Stitched the pieces together to create the panel profiles I want

6. Added a radius value to the edges

7. Thickened then removed faces to allow them to fold out flat.

8. Generated the individual sheet metal parts

The front and left face parts will flatten correctly but the right and back do not.

The back panel wont accept the same radius value as the others so I decreased it and still it wont flatten?

I've tried increasing/decreasing the gap between the flanges on the bottom to allow for more edge/less edge length

I believe it has something to do with how the bottom flanges on the front and back parts terminate at each end of the bend line, but I'm at a loss on how to deal with it?

Or if I'm on the right path?

Any input is appreciated.

Thanks,

This is the actual verbiage of the error message

'a blend may not be set on the boundary of a sheet body'

Uploaded a new file  (01312023) perhaps this will work better.

[Warmingup1953]

I'm getting an "Unable to Open" message on that.  Try as .f3z perhaps

[laughingcreek]

it will be a bit before some of us can open the file.  you got a fusion update that hasn't been pushed out to everyone yet.  I'm still on ver  2.0.15050

[Warmingup1953]

Ahh...That explains...I'm on 2.0.15050 x86_64 here in 'Oz!

[Warmingup1953]

While we wait patiently to be Pushed an Update so we are on par versions with you are you intending to actually make this "Stone" in Sheet metal?

[terry_fusion]

1. My bad, and apologies.

I just updated and had forgotten when I uploaded 🙄

Not in any hurry for advice, this project it still ways out but I like to get ahead of them just in case I run into any issues. Such as this.

1. Yes, as far as its spec'd now it will be 1/8 cor-ten steel.

Eventually there will be 15-20 sets (3 in a  set) of these going up around various locations.

Thanks for reaching out 👍

[laughingcreek · Accepted solution]

fusion finally updated for me.

I only looked at "right face", but the other one probably has a similar problem.

this post on the right face sheet metal part is the issue-

a close up-

generally a good idea to strip the fillets of naked edges. I added these features to your model-

after which I had to edit, but not do anything to(as in edit and then hit ok) the associated thicken feature to get the change to take.

after that the part would un-fold. model attached.

[terry_fusion]

Thanks for taking a look at it for me.

I'm looking at it now processing what you did there, and making sure I understand it.

I had an inclination it was something like that, just wasn't clear on how to deal with it.

Cheers