I am using SW2011 with SP3.
Unfortunately, I cannot post this part due to proprietary reasons but I am hoping for suggestions on where to look.
I have developed a sheet metal part. The part has no errors. The drawing for the part including the flat pattern has no errors. I exported the part with Save Bodies to create a water jet flat pattern. The exported part and its drawings have no errors.
I also mirrored the original part to make an opposite handed version. In the mirrored part I converted to sheet metal so that I can derive a flat pattern. This part has no errors and the part will flatten.
I created a drawing of the mirrored part. The flat pattern view in the drawing causes the error "The geometry in the bend region is too complex."
What is interesting is that the Convert-Solid feature in the part file itself does not throw an error. But it does when you expand the feature tree in the drawing.
This is not a particularly complex piece of sheet metal. It is, however, complex in its derivation. None of the bends are at 90° and it is created with references to several other parts of the assembly.
Not quite sure where to look since it falls apart somewhere between the part file and the drawing file. I have another sheet metal part that is built in exactly the same manner - mirror and all - with different dimensions and it works fine. If anyone has suggestions for typical areas I should look at I would appreciate it. I have changed the bend relief notches as a first attempt.