Unfolding sheet metal components with different rads.

[JeffAtIssyFab]

Hey all, I have a chassis that we are breaking down for laser cutting and I am having difficulty on one specific part. I have a side panel that has a 4" rad and an 8" rad on the same panel. For whatever reason I cannot get this part to unfold or create a flat pattern. I have verified the thickness is uniform front to back. The panel is only one sheet metal component, so I am not sure where or what I am doing wrong. Any help? Thank you. 

[TheCADWhisperer]

@JeffAtIssyFab 

Can you File>Export your *.f3d file to your local drive and then Attach it here to a Reply?

Did you use Sheet Metal tools to create the geometry?

Are cut edges perpendicular to the flat face?

[JeffAtIssyFab]

Hey Whisperer, 

I've derived the part into a separate file as the complete file is exceptionally large. It is just a body in this file but converting it to sheet metal and trying to unfold gives me the exact same issues. 

I did not use sheet metal tools to create it, we projected the shape from the top cap of the rail and then offset that line the thickness of the material we are using (.135").

[TrippyLighting]

When trying to convert this into a sheet metal body, I cannot even pick a single face as the source.
We need to see a timeline to evaluate how this was created.

Remove all scanned meshes so the file isn't huge!

[johnsonshiue]

Hi! I suspect there is some imprecision at the Bend zones. Either the thickness is inconsistent or the bend center axes misalign. I used Delete command to remove the Bends. Then recreate the Bends using Fillet command. The resultant Sheet Metal body can be unfolded. Please take a look.

Many thanks!