Sheet metal part unfolds but errors in flat pattern

[Sophi9999]

Hello,

I have a curved sheet metal part that will unfold.

Once unfolded, I cut a shape and add a hole.

I want to make a flat pattern for laser cutting, but it errors on this operation, saying there is a compute problem.

Workflow is in screen cast and f3d is attached. Thanks in advance! 

[daniel_lyall]

It is the intersect extrude doing it (your second extrude on the timeline) draw a squire around the cut sketch and edit the extrude and select the area inside the squire as the cut tool instead of intersect.

@jeff_strater Could you please have a look at this.

Example attached.

[Sophi9999]

I tried this suggestion - using cut instead of intersect.

I am able to unfold but I am still unable to export a dxf. 

Any ideas why?