Radius sheet metal with taper sizes not flattening.

[jasonlthornton]

I'm trying to cut a profile from a radius plate. I was able to do this with straight sides by creating a cylinder, converting to sheet metal, make the cut profile into a body, splitting the face using the profile body as a splitting tool, and negatively pressing the area I don't want by one thickness. This worked no problem.

I was asked to update the profile and taper the profile sides. I used the same method and the thickness looks good on the part but when I go to flatten it gets a computation error. Is there a better way to do this?

[HughesTooling · Accepted solution]

Not 100% sure why but with the taper the side of the part are not flat but must have a small twist. You can see this if you right click on the face, there's no option to create a sketch or plane.

I modified your design and added a small tag on one end without a taper, you can make this smaller than I have here. I then extruded a small flat to use as the stationary face for the flat pattern. Again you can make these very small after setting it up.

And flat pattern.

[jasonlthornton]

That fixed it! I was thinking there had to be a twist or bevel somewhere to cause the issue, but the taper was too light to find it.