Try to suppress two last cuts and force Sw to rebuild whole model with CTRL+Q. Check if you will get flatt pattern. I think at there is some issues with one of those cuts.
It is the second last cut. It edns "on" bend. You can change it to cut trough whole bend or end it just before bend... (0,001 inch for example).
My god, that worked! Thanks a million, I tried suppressing/deleting the last cuts yesterday but I guess solidworks didn't recognize the change because I wasn't hitting control-q.
Retrieving data ...