How to Create Flat Pattern in SolidWorks: Step-by-Step Guide

To create a Flat Pattern in SolidWorks, first design your part using the Sheet Metal features like Base Flange or Edge Flange. Then, use the Flatten tool in the Sheet Metal tab to unfold the part into a flat pattern for manufacturing or drawing.

Syntax

Creating a flat pattern in SolidWorks involves these main steps:

• Create Sheet Metal Part: Use Base Flange/Tab or Convert to Sheet Metal features.
• Apply Sheet Metal Features: Add bends, flanges, and cuts as needed.
• Flatten the Part: Click the Flatten button in the Sheet Metal toolbar to generate the flat pattern.

Each step uses specific commands found in the Sheet Metal tab of the SolidWorks interface.

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1. Insert > Sheet Metal > Base Flange/Tab
2. Add bends and flanges using Sheet Metal tools
3. Click Sheet Metal > Flatten

Example

This example shows how to create a simple sheet metal box and generate its flat pattern.

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1. Open a new part in SolidWorks.
2. Go to Insert > Sheet Metal > Base Flange/Tab.
3. Sketch a rectangle (e.g., 100mm x 50mm) and set thickness (e.g., 2mm).
4. Use Edge Flange to add flanges on the sides (e.g., 20mm height).
5. After completing the design, click the Flatten button in the Sheet Metal toolbar.
6. The part will unfold showing the flat pattern ready for manufacturing.

Output

Flat pattern view of the sheet metal box showing all bends unfolded into a flat shape.

Common Pitfalls

• Not starting with a Sheet Metal feature causes flattening to fail.
• Using non-sheet metal features like extrudes without converting can prevent flat pattern creation.
• Forgetting to define bend radius or thickness leads to inaccurate flat patterns.
• Trying to flatten parts with complex non-sheet metal geometry will cause errors.

Always start with Sheet Metal tools and check parameters before flattening.

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Wrong approach:
1. Create a simple extruded part (not sheet metal).
2. Try to flatten - no option available.

Right approach:
1. Use Base Flange/Tab to start sheet metal part.
2. Add features.
3. Use Flatten button successfully.

Quick Reference

Step	Action	Location in SolidWorks
1	Create Base Flange/Tab	Insert > Sheet Metal > Base Flange/Tab
2	Add Edge Flanges or Bends	Sheet Metal tab > Edge Flange
3	Set Thickness and Bend Radius	Sheet Metal feature properties
4	Flatten Part	Sheet Metal tab > Flatten button
5	Create Flat Pattern Drawing	Right-click Flat Pattern in Feature Manager > Make Drawing from Part

Key Takeaways

Always start your design with Sheet Metal features like Base Flange for flat pattern capability.

Use the Flatten tool in the Sheet Metal tab to generate the flat pattern automatically.

Define correct thickness and bend radius to ensure accurate flat patterns.

Avoid using standard extrudes or non-sheet metal features if you want to create flat patterns.

Use the flat pattern for manufacturing drawings or CNC cutting layouts.