I have a sheet metal panel from a vendor of mine. They created it in Pro/e. The corner is nice and rounded and with a simple tac weld the corners are as strong as if they were fully welded and they look like they had been welded and ground. I recently came up with my own rounded corner that has worked so far in production but the ripping that is formed in the flat pattern leaves a much larger void in the corner pocket. The SM house will make adjustments on their side to close up the hole but I want to be able to make my part reflect the correct way that they will be doing it.

Any thoughts on cleaning it up?