Sheet metal modeling in SolidWorks has its own logic, and a part that looks perfectly reasonable in the folded 3D view can still produce a flat pattern that doesn't match reality. One common mistake is ignoring K-factor and bend allowance settings, or using SolidWorks' defaults without checking them against your actual material and process. Bend allowances vary by material, thickness, and bend radius — get this wrong and your flat pattern dimensions will be off, sometimes just enough to cause real problems in fabrication. Another frequent issue is adding features in the wrong order relative to the base flange and bends, which can produce unfold errors or distorted flat patterns. It's usually safer to build the base flange and primary bends first, then add edge flanges, hems, and cosmetic features afterward. Finally, many designers under-communicate bend direction and relief style to manufacturing, relying on the 3D model alone. A clear flat pattern drawing, with bend lines, direction, and relief style labeled, saves a lot of back-and-forth with the shop floor — and catches problems before metal gets cut.