Flat Pattern of Fan Blade

[sloth4z]

I am trying to figure out the flat pattern of the blade for the following fan. I have been successful in creating the solid model, but I cannot figure out how to make the blade into sheet metal. I have tried several methods and the closest I got was making the blade out of a surface (using multiple trim features), and then thickening the blade. I should be able to make the blade from two bends. No matter what I try I cannot get the bottom portion of the blade to bend properly. Can you guys offer any suggestions on how to do this correctly?

 

[CorBlimeyLimey]

Can you post the fin file for download?

 

[Luca83]

Just as a thought... Those fins could be created by using a sheetmetal loft then using whatever series of cuts to your calculated shape of the fin, then you can generate a flat pattern.

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[CorBlimeyLimey]

If you are using the surface of the main body (the funnel shape) to cut the fins, the resultant cut will create a bevelled edge on the fin, and that will prevent the fin being flattened.

You will need to somehow make a "normal" cut across the fin.