I am having trouble getting the part to flatten. Originally the part had a continuous linear edge (right image) which intersected a number of the cutouts. The problem is that when you wrap the template around a tube the openings do not always line up nicely and it makes it more difficult to scribe around the perimeter of the opening. Therefore, i wanted to adjust the cut edge so that none of the opening get divided. I unfolded the base flange and added a triangular extrude and cut-extrude to create the chevron shape. There is still a straight line segment at each end that the unfolded edge is applied to. I folded the base flange back up and the pattern cutout just fine. However, when you try to flatten the part you get the error that flat pattern has features that cannot be unfolded. Any cutout (red) that passes over the original continuous edge causes the error.
I am trying to maintain the integrity of the model since it drives the location of part in an upper level assembly. Does anyone have any ideas on how this could be done? In theory there shouldn't be a problem but it has something to do with the way solidworks handles the fixed edge.