The four parts had a common error associated with the notch on the end of the part. The 3D view is correct, however, the SW flattening logic did not process the geometry correctly.
The following documents the 3D to 2D errors:
The ½” tab on the end of the part is stretched down and beveled as displayed in the flat below.
Below we see the dimensioned part, with the error, in PEP.
The gap error can be corrected in PEP in seconds, or the user can return to SolidWorks from within PEP, flatten the part and fix it in SolidWorks.
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