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having trouble generating flat pattern

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Hi all,

I am trying to generate a flat pattern for a "sheet metal" part and not having any luck.

The modeling technique used a combination of surfaces that were merged together and made solid using the thicken command.

the boundary blend surface seems to be causing the flat pattern to choke.

I was unable to flatten the quilt using "flatten quilt" either.

 

Attached zip file contains part generated in Creo 2.0  if you are interested in taking a crack at it in a earlier version, let me know and I will rebuild the model.

 

Any suggestions or work around?

Should you come up with a working solution, you will be rewarded with my admiration and gratitude...

Thanks

Scott Larsen


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