Hello,
I have been racking my brain on this and can't seem to figure it out. I have a sheetmetal (3/16") part that I need to replace for a customer, it has two different bend lines and is also smaller on one side than the other. I have a surface loft that seems to be correct for the dims, but now I cant convert to sheetmetal so that I can flatten it and give to the shop guys to fab. Each time I try to convert to sheet metal I get the error about non-planer faces
I am using SW 14 standard.
Third time is a charm (maybe) I altered the profiles slightly so we would end up with planer surfaces. Now it unfolds, no reliefs, and there are bend lines. I used a .125 bend radius. The bodies don't line up exactly but are really close and after all, it is sheet metal. I'm sure you could change things a tad and get everything within .020. Right now I'm maximum out within .045 of your model and that is in one corner. Check it out.
Edit:.. I got it within .028 which ain't bad for .188 material.
Edit:... Now within .001