Okay, first I'd like to make it clear that I'm no sheet metal feature expert.  I've just never really had the need to use it a lot.  So I only ever learned the basics.

Occasionally, we are required to show packaging of our products in our drawings.  So I have had this "box" template that I use regularly to create box models, just to represent the final packaging.  I have 3 configurations: Default (closed), SM-Flat Pattern (derived config of Default), and Lid Open.  The Lid Open config simply shows the box with the top lids open at a 45° angle.  I've used this template many times in the past without any major problems.  It's just that changing the size of the box was a little difficult with the equations that I had set up.  Basically, I have 3 global variables setup for LxWxH that the equations were supposed to evaluate to create the correct size box.  The equations didn't work exactly right so I always had to "lie" a little in the global variables to get the exact size box that I needed.

I had a little free time so I thought I would create a copy of this template, analyze these equations carefully, and correct them.  I got them corrected fine, and the equations will now create the correct size box based on the 3 global variable inputs.

However, for some reason, now, when I try to change to the Flat Pattern config, I get one bend that won't seem to unbend.  The physical geometry of the box is identical to the old box template as best I can tell (geometry compare fails).

Can I beg some of you sheet metal gurus out there to take a look at these 2 templates and tell me what I'm doing wrong?  Like I said, geometrically they appear to be identical.  So I'm at a loss as to why it won't unbend now.