Trouble creating flat pattern
Earlier I suggested downloading the Service Packs (there are 2).
In Post #32 your file indicated that it was created in Service Pack 1.
In Post #40 your file indicated that it was created in Service Pack 0?
Are you using two different computers?
The next question might be a bit difficult to understand and answer.
Refer to the image below.
You have 5 different arc radii.
How will your part be manufactured?
Will you be doing the actual bending?
Will someone else inside your company be doing the actual bending?
Will someone outside of your company be doing the actual bending?
If you make the arcs tangent (currently they are not) there will not be any clear transition between bend arcs. I assume you do not want this - that there should be bends between the arcs).
If you do not add tangents there will be definite bend lines (let's call them creases) between the large arcs.
I assume this is what you want - but I need to know before proceeding.