Trouble creating flat pattern from ipt

[hruska_isaac]

I am trying to design a oddly shaped base plate for my robotics team and am having trouble unfolding the part to cut on our CNC plasma table. I have tried offsetting the faces and then thickening to get the right thickness. It was created in an assembly, converted to ipt, and now trying to get it flat in sheet metal. I got it to fold 3 out of the 4 bends. Instead of bending the last bend it just smushes it flat horizontally. Any help is appreciated. 

The track drive file is just for reference, FrontPlate is the part, and FrontPlateAttemptFold is the 3/4 fold.

[James_Willo · Accepted solution]

Hi, where did you get the original shape from? There are loads of things stopping this flattenning. 

No bend reliefs

Your fillets are the wrong size for the sheet metal rule. (should be 0.1)

Should be 0.2

Some corners with no fillet.

And I don't know what happened here?

Also the edge of the sheet isn't square

[James_Willo · Accepted solution]

Please find attached a plate that will flatten. 

[hruska_isaac]

I created to original shape by sketching and extruding in the assembly. Then used extrusions to cut the holes and other shapes out. Thank you so much for your help.