Hello All,

This is my first post, so bear with me.

I have a multi-configuration cone for a project that I am currently working on. In all, there are 69 different sizes. I am running into an issue with cone sizes that have diameters which approach  each other. I have had very good luck so far with the sheet metal flat patterns, both in solidworks and on our shop floor, but typically, the top two sizes (see attached) for each cone model have the same issue. The error is associated with Round Bend 1 under Flatten Bends1. The warning message states that the geometry in the bend region is too complex. 

I can always just make a 2D drawing by manually calculating the cone flat pattern, but I would much rather prefer utilizing the configuration in Solidworks if possible.

After opening the file, click on TIB 080,100,120 Cone C or D configuration...then click on configuration TIB 080,100,120 Cone J or K...I think this will show you the exact issue I'm talking about.

If I am being to vague, please let me know.

Thank you in advance for any help.