Inside Sheet Metal, the created model fails to flat pattern. Several steps need do be ensured in order for the part to flat pattern successfully.
1. Ensure consistent thickness throughout the model before attempting to flat pattern.
2. Ensure the thickness of the model is exactly the same as the "Sheet Metal Style". If creating sheet metal from a surface, use the "Thicken" tool to obtain sheet metal of uniform thickness.
3. The model cannot be continuous (fully closed loop). A gap must be left to allow unfolding of
the created sheet metal part. If a continuous part has been already created, use Inventors "Rip" tool to create the required gap.
4. Ensure there are no overlapping folds. Autodesk sheet metal environment will detect overlapping folds and display the error until its resolved. You may still flat pattern with this issue unresolved, but it is advised to fix the issue first to prevent any problems that may derive from this error.
5. Ensure the edges of the sheet metal are perpendicular to the face. If the edges are not perpendicular, the flat pattern option may not work. Using "Thicken" tool should prevent any twisted edges that may prevent the unfolding operation.
6. Ensure the external corners of the model to be unfolded are filleted. The flat pattern feature will not work with sharp 90 degree corners.
7. Sometimes you may find yourself working with a model created in a third party software. The process of converting such part to flat pattern is pretty straight forward but my not be possible in all cases.
- Open the model created by the third party software and proceed to "Sheet Metal Environment
- Ensure the Thickness is exactly the same as in the model. Select base face and select "Ok"
- Now you can create flat pattern as usual. No additional procedures are required.