Does anyone find Sheet Metal Unbending problematic?

In the past I was able to adjust tolerances within user options so that my sheetmetal walls will unbend, but with the latest upgrade (Creo 3.0/M120) I cannot find the option and my walls will not unbend.  No matter what I've tried, the issue persists - not with all walls, but occasionally one will fail and prevent a flat pattern unbend - I've recreated them by every means available, but no luck. Very annoying!  My work does not depend upon tight tolerances or bend relief or offsets - in fact on the contrary, it is not sheetmetal at all, but thin plastics.  We just need to end up with a flat pattern that can be cut by hand or converted to .dxf for Gerber cutting.

Any suggestions will be greatly appreciated!