I keep getting this error on a rolled sheet metal part while trying to flatten and/or unfold. 
I've tried everything I can think of and I cannot understand why it is still giving me this error. I need to flatten this for a customer to be able to laser cut it.
I've attached the file in question in its entirety. this ultimately gets placed into an assembly but there should be no external references. I've even gone to the extent of contacting my companies solidworks dealer (who also does extensive solidworks training classes with certified instructors) and they can't even figure this out.
Hi Brad,
In order to flatten a sheet metal piece the model needs to either have 1) a flat face to flatten from or 2) one of the original edges created on the initial creation of the base flange. In your model you have no flat faces so you need to have one of those original edges from the base flange feature. From the looks of it Cut-Extrude5 and Cut-Extrude6 cut these off. If you adjust either side so some small amount of the original flange edge remains (like in Cut-Extrude5 don't extend the flange then cut it off; create the flange so you just need to add a fillet and cut the lower section out).
In your model I was able to edit the sketch of Cut-Extrude6 so that it was offset infinitesimally from the corner it is currently coincident on. Now the flat pattern generates. Check out the attached model for that edit.