[Rich05]

when flattening this i noticed a small cut on one side. what gives why is this placing a small cut on one side?

[bobva98903]

The small cut is most likely bend relief being put in by solidworks. Right click on the particular flange and select "edit feature". Go down to custom relief, click on the box so that the drop down menu goes down and select "tear" from the bend relief options. That should remove the slot.

[JerryFlyGuy]

Close.. but not quite. It depends on how the part was made.. if it was modeled in it's formed state and then 'insert bends' was used.. your stuck.. there isn't a function that I know of to extend that lip so it doesn't tear or put in the relief.. however if you do it the way sheet metal was intended [well the new way.. not the old way ] you have the option of removing those relief's when you make the edge flanges.. to remove them, you have to select that little button on the right side.. when you see it you'll understand... the button on the left show's the relief.. the one on the right shows it removed..

see the attached picture..

J