The only way I've been able to use surfaces with complex curvature to generate things like flat patterns is to use surfaces. It's kind of crude, but I do these steps:
(1) Create a surface at the mid thickness of the "sheet" of the part. An offset surface.
(2) Use the "flatten quilt" function to make a planar surface from the curved one.
(3) Use this flat surface to make my flat pattern (by making a solid protrusion using it).
It's an approximation of reality, since it doesn't take into account things like localized thinning of the material when it is formed, etc. But for the types of things we do it's good enough.