trying to make a sheet metal conversion of part for laser cutting + forming

[bicanekP3V9Q]

i designed an intercooler end tank, that I plan on forming with a 3d printed press tool.  Since its a 3d printed tool, i do not think i would be able to from the bottom area as i will not be able to apply heat to the material.  I want to instead use this model, cut a relief here, and flatten it into something that i could get waterjet cut.  How would i go about doing this?  Here is the fusion model: https://a360.co/3SMNPrp

Workflow was extruding a flat sketch, adding a radius, then taking the surface model and thickening it 1.5mm.

[Warmingup1953]

What material and gauge will you use in real life? Why not just omit the part spherical area (x2)?

[bicanekP3V9Q]

~.060” aluminum (1.5mm). 

what do you mean “remove the spherical part”? 

[Warmingup1953]

Like this:

And then finesse into a sheet metal body

Edit: A few doodles included WIP of course Thickness is incorrect etc

[laughingcreek]

the way these variable fillets were formed doesn't conform to the sheet metal rules in fusion.  you won't be able to unfold this.

[bicanekP3V9Q]

interesting.  I used the filet tool to make the filet. Is there a better way?  Looks like i may just have to 3d print this model, make a fabric or paper template and then model that.

[Warmingup1953]

You could create a flat pattern from my "effort" above where I have attached a WIP Fusion file.