You probably need to change the notch so that the inside arc of the bend clears the 180° bend edges.
A better way is to extrude the 90° bend first, then add the return bend as a Mitre-Flange.
Here is the file if anyone want to play about with it.
Going to try the mitre flange see if i can get that to work
You need to change how you do the extrude1 cut. SW can't create the bend with the cut you have originally. This would require part deformation, a non-guassion type bend.
SW can only do simple brake press formed bends. Even though what you want to model will probably work in your brake press, the metal deformation required can't be modeled in SW the way you are trying with your SW feature selections.
See attached model.....
Thanks Anna iam going to be popular at work with this one.
Iam going to insert a easy bend i call it , the sketched bend will be a series of punched small retangles down the side to enable bending bye hand i can manufactor the hem and bends no probs.
Is there anyway to decrees the size of the gap at the mitre.
You have to decrease the size of the bend radius, then make the notch as small as you can before the sketch bend feature fails.
Or just add extra material to fill the gap to get the look you want for a finished part. Use configurations to suppress/unsuppress features as needed to get the finished part and what you need to create tooling. The part for setting tooling doesn't need to look like the finished part.
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