I've got a frame for a product that we make in house and need to modify the tooling to fir the redesign. First, it must be modeled and a flat pattern needs to be generated. The problem is, I can't model the internl rib in the box frame. Has anyone had to model something similar that I could look at? I've tried starting with a solid model, starting witht the flattened model, starting as a sheet metal part, etc.
Check out this one. The trick is to prevent the bend radiuses from blending into complex surfaces at the ends of the rib. The flat face NEEDS to separate the rib bend from the corner bend of the frame.