Alright guys, help me out with this one. I opened this part (C-15829) that we have not used in I don't know how long, and the person that made it did some weird stuff. The part opens fine and looks good, but when you look at the configurations the flat pattern indicates that it has rebuild errors (not too surprising since a lot of these older parts were not initially made using sheet metal features). But you will notice that there is an additional configuration titled "Flat" where the flat pattern works just fine. I played with the "Default" configuration and the flat pattern works fine. However, when looking at the flat pattern that is a sub-configuration of the "Default" config, the Convert-Solid1 feature will not rebuild and indicates that "The geometry in the bend region is too complex".

I can still use this part and everything is good, but this little error has really got me scratching my head and I wanted to see if anyone understands why it is throwing the error. I don't know about anyone else, but for me, rebuild errors in my feature tree are like an annoying little itch.

I am also not sure what the Body-Delete1 feature was used for here. I am not very familiar with that feature. 

I have attached a copy of the part below.

Thanks in advance for any input.