I downloaded the codestack dxf file export for assemblies.  It worked great for the first couple of times I used it. 

My models utilize Global Variables at the top level. I use these top level models as a project template, but using pack n go's, then find and replace the naming convention.  

After doing this a couple of times, the macro now fails and will not complete. 

Any ideas or insight would be greatly appreciated.  

The code below:

'**********************
'Copyright(C) 2025 Xarial Pty Limited
'Reference: https://www.codestack.net/solidworks-api/document/sheet-metal/export-all-flat-patterns/?utm_source=chatgpt.com
'License: https://www.codestack.net/license/
'**********************

Enum SheetMetalOptions_e
   ExportFlatPatternGeometry = 1
   IncludeHiddenEdges = 2
   ExportBendLines = 4
   IncludeSketches = 8
   MergeCoplanarFaces = 16
   ExportLibraryFeatures = 32
   ExportFormingTools = 64
   ExportBoundingBox = 2048
End Enum

Const SKIP_EXISTING_FILES As Boolean = False

Const OPEN_APP_PATH As String = "" 'Path to the application to open the file (e.g. eDrawings), empty string to not open the file, * to open with default application

Const OUT_NAME_TEMPLATE As String = "DXFs\\<_FileName_>_<_FeatureName_>_<_ConfName_>_<\\\$CLPRP:Description>.dxf"

Const FLAT_PATTERN_OPTIONS As Integer = SheetMetalOptions_e.ExportBendLines + SheetMetalOptions_e.ExportFlatPatternGeometry

Dim swApp As SldWorks.SldWorks

Sub main()
       
   Set swApp = Application.SldWorks
   
try_:
   On Error GoTo catch_
   
   Dim swModel As SldWorks.ModelDoc2
   Set swModel = swApp.ActiveDoc
   
   If swModel Is Nothing Then
       Err.Raise vbError, "", "Please open assembly or part document"
   End If
   
   If swModel.GetType() = swDocumentTypes_e.swDocASSEMBLY Then
   
       Dim swAssy As SldWorks.AssemblyDoc
       
       Set swAssy = swModel
           
       swAssy.ResolveAllLightWeightComponents True
           
       Dim vComps As Variant
       vComps = GetDistinctSheetMetalComponents(swAssy)
       
       Dim i As Integer
       
       For i = 0 To UBound(vComps)
       
           Dim swComp As SldWorks.Component2
           Set swComp = vComps(i)
           
           ProcessSheetMetalModel swAssy, swComp.GetModelDoc2(), swComp.ReferencedConfiguration
       
       Next
       
   ElseIf swModel.GetType() = swDocumentTypes_e.swDocPART Then
       
       Dim swPart As SldWorks.PartDoc
       Set swPart = swApp.ActiveDoc
       
       ProcessSheetMetalModel swPart, swPart, swPart.ConfigurationManager.ActiveConfiguration.Name
       
   Else
       Err.Raise vbError, "", "Only assembly and part documents are supported"
   End If
   
   swApp.SendMsgToUser2 "Operation completed", swMessageBoxIcon_e.swMbInformation, swMessageBoxBtn_e.swMbOk
   
   GoTo finally_
   
catch_:
   swApp.SendMsgToUser2 Err.Description, swMessageBoxIcon_e.swMbStop, swMessageBoxBtn_e.swMbOk
finally_:

End Sub

Function GetDistinctSheetMetalComponents(assy As SldWorks.AssemblyDoc) As Variant
   
   Dim vComps As Variant
   vComps = assy.GetComponents(False)
       
   Dim i As Integer
   
   Dim swSheetMetalComps() As SldWorks.Component2
   
   For i = 0 To UBound(vComps)
       
       Dim swComp As SldWorks.Component2
       Set swComp = vComps(i)
               
       If False = swComp.IsSuppressed() Then
           
           If Not ContainsComponent(swSheetMetalComps, swComp) Then
               
               If IsSheetMetalComponent(swComp) Then
                   If (Not swSheetMetalComps) = -1 Then
                       ReDim swSheetMetalComps(0)
                   Else
                       ReDim Preserve swSheetMetalComps(UBound(swSheetMetalComps) + 1)
                   End If
                   
                   Set swSheetMetalComps(UBound(swSheetMetalComps)) = swComp
               End If
           
           End If
           
       End If
       
   Next
   
   If (Not swSheetMetalComps) = -1 Then
       GetDistinctSheetMetalComponents = Empty
   Else
       GetDistinctSheetMetalComponents = swSheetMetalComps
   End If
   
End Function

Function IsSheetMetalComponent(comp As SldWorks.Component2) As Boolean
   
   Dim vBodies As Variant
   vBodies = comp.GetBodies3(swBodyType_e.swSolidBody, Empty)
   
   If Not IsEmpty(vBodies) Then
       
       Dim i As Integer
       
       For i = 0 To UBound(vBodies)
           Dim swBody As SldWorks.Body2
           Set swBody = vBodies(i)
           
           If False <> swBody.IsSheetMetal() Then
               IsSheetMetalComponent = True
               Exit Function
           End If
           
       Next
   End If
   
   IsSheetMetalComponent = False
   
End Function

Function ContainsComponent(comps As Variant, swComp As SldWorks.Component2) As Boolean

   Dim i As Integer
   
   For i = 0 To UBound(comps)
       Dim swThisComp As SldWorks.Component2
       Set swThisComp = comps(i)
       
       If swThisComp.GetPathName() = swComp.GetPathName() And swThisComp.ReferencedConfiguration = swComp.ReferencedConfiguration Then
           ContainsComponent = True
           Exit Function
       End If
   Next
   
   ContainsComponent = False

End Function

Function ComposeOutFileName(template As String, rootModel As SldWorks.ModelDoc2, sheetMetalModel As SldWorks.ModelDoc2, conf As String, flatPatternFeat As SldWorks.Feature, cutListFeat As SldWorks.Feature) As String

   Dim regEx As Object
   Set regEx = CreateObject("VBScript.RegExp")
   
   regEx.Global = True
   regEx.IgnoreCase = True
   regEx.Pattern = "<[^>]*>"
   
   Dim regExMatches As Object
   Set regExMatches = regEx.Execute(template)
   
   Dim i As Integer
   
   Dim outFileName As String
   outFileName = template
   
   For i = regExMatches.Count - 1 To 0 Step -1
       
       Dim regExMatch As Object
       Set regExMatch = regExMatches.Item(i)
                   
       Dim tokenName As String
       tokenName = Mid(regExMatch.Value, 2, Len(regExMatch.Value) - 2)
       
       outFileName = Left(outFileName, regExMatch.FirstIndex) & ResolveToken(tokenName, rootModel, sheetMetalModel, conf, flatPatternFeat, cutListFeat) & Right(outFileName, Len(outFileName) - (regExMatch.FirstIndex + regExMatch.Length))
   Next
   
   ComposeOutFileName = ReplaceInvalidPathSymbols(GetFullPath(rootModel, outFileName))
   
End Function

Function ReplaceInvalidPathSymbols(path As String) As String
   
   Const REPLACE_SYMB As String = "_"
   
   Dim res As String
   res = Right(path, Len(path) - Len("X:\\"))
   
   Dim drive As String
   drive = Left(path, Len("X:\\"))
   
   Dim invalidSymbols As Variant
   invalidSymbols = Array("/", ":", "*", "?", """", "<", ">", "|")
   
   Dim i As Integer
   For i = 0 To UBound(invalidSymbols)
       Dim invalidSymb As String
       invalidSymb = CStr(invalidSymbols(i))
       res = Replace(res, invalidSymb, REPLACE_SYMB)
   Next
   
   ReplaceInvalidPathSymbols = drive + res
   
End Function

Function ResolveToken(token As String, rootModel As SldWorks.ModelDoc2, sheetMetalModel As SldWorks.ModelDoc2, conf As String, flatPatternFeat As SldWorks.Feature, cutListFeat As SldWorks.Feature) As String
   
   Const FILE_NAME_TOKEN As String = "_FileName_"
   Const ASSM_FILE_NAME_TOKEN As String = "_AssmFileName_"
   Const FEAT_NAME_TOKEN As String = "_FeatureName_"
   Const CONF_NAME_TOKEN As String = "_ConfName_"
   
   Const PRP_TOKEN As String = "\\\$PRP:"
   Const CUT_LIST_PRP_TOKEN As String = "\\\$CLPRP:"
   Const ASM_PRP_TOKEN As String = "\\\$ASSMPRP:"
   
   Select Case LCase(token)
       Case LCase(FILE_NAME_TOKEN)
           ResolveToken = GetFileNameWithoutExtension(sheetMetalModel.GetPathName)
       Case LCase(FEAT_NAME_TOKEN)
           ResolveToken = flatPatternFeat.Name
       Case LCase(CONF_NAME_TOKEN)
           ResolveToken = conf
       Case LCase(ASSM_FILE_NAME_TOKEN)
           If rootModel.GetPathName() = "" Then
               Err.Raise vbError, "", "Assembly must be saved to use " & ASSM_FILE_NAME_TOKEN
           End If
           ResolveToken = GetFileNameWithoutExtension(rootModel.GetPathName())
       Case Else
           
           Dim prpName As String
                       
           If Left(token, Len(PRP_TOKEN)) = PRP_TOKEN Then
               prpName = Right(token, Len(token) - Len(PRP_TOKEN))
               ResolveToken = GetModelPropertyValue(sheetMetalModel, conf, prpName)
           ElseIf Left(token, Len(ASM_PRP_TOKEN)) = ASM_PRP_TOKEN Then
               prpName = Right(token, Len(token) - Len(ASM_PRP_TOKEN))
               ResolveToken = GetModelPropertyValue(rootModel, rootModel.ConfigurationManager.ActiveConfiguration.Name, prpName)
           ElseIf Left(token, Len(CUT_LIST_PRP_TOKEN)) = CUT_LIST_PRP_TOKEN Then
               prpName = Right(token, Len(token) - Len(CUT_LIST_PRP_TOKEN))
               ResolveToken = GetPropertyValue(cutListFeat.CustomPropertyManager, prpName)
           Else
               Err.Raise vbError, "", "Unrecognized token: " & token
           End If
           
   End Select
   
End Function

Function GetModelPropertyValue(model As SldWorks.ModelDoc2, confName As String, prpName As String) As String
   
   Dim prpVal As String
   Dim swCustPrpMgr As SldWorks.CustomPropertyManager
   
   Set swCustPrpMgr = model.Extension.CustomPropertyManager(confName)
   prpVal = GetPropertyValue(swCustPrpMgr, prpName)
   
   If prpVal = "" Then
       Set swCustPrpMgr = model.Extension.CustomPropertyManager("")
       prpVal = GetPropertyValue(swCustPrpMgr, prpName)
   End If
   
   GetModelPropertyValue = prpVal
   
End Function

Function GetPropertyValue(custPrpMgr As SldWorks.CustomPropertyManager, prpName As String) As String
   Dim resVal As String
   custPrpMgr.Get2 prpName, "", resVal
   GetPropertyValue = resVal
End Function

Function GetFileNameWithoutExtension(path As String) As String
   GetFileNameWithoutExtension = Mid(path, InStrRev(path, "\\") + 1, InStrRev(path, ".") - InStrRev(path, "\\") - 1)
End Function

Function GetCutListFeatures(model As SldWorks.ModelDoc2) As Variant
   GetCutListFeatures = GetFeaturesByType(model, "CutListFolder")
End Function

Function GetFlatPatternFeatures(model As SldWorks.ModelDoc2) As Variant
   GetFlatPatternFeatures = GetFeaturesByType(model, "FlatPattern")
End Function

Sub ProcessSheetMetalModel(rootModel As SldWorks.ModelDoc2, sheetMetalModel As SldWorks.ModelDoc2, conf As String)

   Dim activeConfName As String

   Dim error As ErrObject

try_:
   
   On Error GoTo catch_
   
   activeConfName = sheetMetalModel.ConfigurationManager.ActiveConfiguration.Name
   
   If LCase(activeConfName) <> LCase(conf) Then
       If False = sheetMetalModel.ShowConfiguration2(conf) Then
           Err.Raise vbError, "", "Failed to activate configuration"
       End If
   End If
       
   Dim vCutListFeats As Variant
   vCutListFeats = GetCutListFeatures(sheetMetalModel)
   
   If Not IsEmpty(vCutListFeats) Then
       
       Dim vFlatPatternFeats As Variant
       vFlatPatternFeats = GetFlatPatternFeatures(sheetMetalModel)
       
       If Not IsEmpty(vFlatPatternFeats) Then
           
           Dim swProcessedCutListsFeats() As SldWorks.Feature
           
           Dim i As Integer
   
           For i = 0 To UBound(vFlatPatternFeats)
               
               Dim swFlatPatternFeat As SldWorks.Feature
               Dim swFlatPattern As SldWorks.FlatPatternFeatureData
               
               Set swFlatPatternFeat = vFlatPatternFeats(i)
               
               Set swFlatPattern = swFlatPatternFeat.GetDefinition
               
               Dim swFixedEnt As SldWorks.Entity
               
               Set swFixedEnt = swFlatPattern.FixedFace2
               
               Dim swBody As SldWorks.Body2
               
               If TypeOf swFixedEnt Is SldWorks.Face2 Then
                   Dim swFixedFace As SldWorks.Face2
                   Set swFixedFace = swFixedEnt
                   Set swBody = swFixedFace.GetBody
               ElseIf TypeOf swFixedEnt Is SldWorks.Edge Then
                   Dim swFixedEdge As SldWorks.Edge
                   Set swFixedEdge = swFixedEnt
                   Set swBody = swFixedEdge.GetBody
               ElseIf TypeOf swFixedEnt Is SldWorks.Vertex Then
                   Dim swFixedVert As SldWorks.Vertex
                   Set swFixedVert = swFixedEnt
                   Set swBody = swFixedVert.GetBody
               End If
               
               Dim swCutListFeat As SldWorks.Feature
               Set swCutListFeat = FindCutListFeature(vCutListFeats, swBody)
               
               If Not swCutListFeat Is Nothing Then
                   
                   Dim isUnique As Boolean
                                       
                   If (Not swProcessedCutListsFeats) = -1 Then
                       isUnique = True
                   ElseIf Not ContainsSwObject(swProcessedCutListsFeats, swCutListFeat) Then
                       isUnique = True
                   Else
                       isUnique = False
                   End If
                   
                   If isUnique Then
                       
                       If (Not swProcessedCutListsFeats) = -1 Then
                           ReDim swProcessedCutListsFeats(0)
                       Else
                           ReDim Preserve swProcessedCutListsFeats(UBound(swProcessedCutListsFeats) + 1)
                       End If
                       
                       Set swProcessedCutListsFeats(UBound(swProcessedCutListsFeats)) = swCutListFeat
                       
                       Dim outFileName As String
                       outFileName = ComposeOutFileName(OUT_NAME_TEMPLATE, rootModel, sheetMetalModel, conf, swFlatPatternFeat, swCutListFeat)
                       
                       If Not SKIP_EXISTING_FILES Or Not FileExists(outFileName) Then
                           ExportFlatPattern sheetMetalModel, swFlatPatternFeat, outFileName, FLAT_PATTERN_OPTIONS
                           If OPEN_APP_PATH <> "" Then
                               OpenFile outFileName
                           End If
                       End If
                   End If
                   
               Else
                   Err.Raise vbError, "", "Failed to find cut-list for flat pattern " & swFlatPatternFeat.Name
               End If
               
           Next
           
       Else
           Err.Raise vbError, "", "No flat pattern features found"
       End If
       
   Else
       Err.Raise vbError, "", "No cut-list items found"
   End If
   
   GoTo finally_
catch_:
   Set error = Err
finally_:

   sheetMetalModel.ShowConfiguration2 activeConfName
   
   If Not error Is Nothing Then
       Err.Raise error.Number, error.Source, error.Description, error.HelpFile, error.HelpContext
   End If
   
End Sub

Function FileExists(filePath As String) As Boolean
   FileExists = Dir(filePath) <> ""
End Function

Function FindCutListFeature(vCutListFeats As Variant, body As SldWorks.Body2) As SldWorks.Feature
   
   Dim i As Integer
   
   For i = 0 To UBound(vCutListFeats)
       
       Dim swCutListFeat As SldWorks.Feature
       Set swCutListFeat = vCutListFeats(i)
       
       Dim swBodyFolder As SldWorks.BodyFolder
       Set swBodyFolder = swCutListFeat.GetSpecificFeature2
       
       Dim vBodies As Variant
       
       vBodies = swBodyFolder.GetBodies
       
       If ContainsSwObject(vBodies, body) Then
           Set FindCutListFeature = swCutListFeat
       End If
           
   Next
   
End Function

Function ContainsSwObject(vArr As Variant, obj As Object) As Boolean
   
   If Not IsEmpty(vArr) Then
   
       Dim i As Integer
       
       For i = 0 To UBound(vArr)
           
           Dim swObj As Object
           Set swObj = vArr(i)
           
           If swApp.IsSame(swObj, obj) = swObjectEquality.swObjectSame Then
               ContainsSwObject = True
               Exit Function
           End If
       Next
       
   End If
   
   ContainsSwObject = False
   
End Function

Function GetFeaturesByType(model As SldWorks.ModelDoc2, typeName As String) As Variant
   
   Dim swFeats() As SldWorks.Feature
   
   Dim swFeat As SldWorks.Feature
   
   Set swFeat = model.FirstFeature
   
   Do While Not swFeat Is Nothing
       
       If typeName = "CutListFolder" And swFeat.GetTypeName2() = "SolidBodyFolder" Then
           Dim swBodyFolder As SldWorks.BodyFolder
           Set swBodyFolder = swFeat.GetSpecificFeature2
           swBodyFolder.UpdateCutList
       End If
       
       ProcessFeature swFeat, swFeats, typeName

       Set swFeat = swFeat.GetNextFeature
       
   Loop
   
   If (Not swFeats) = -1 Then
       GetFeaturesByType = Empty
   Else
       GetFeaturesByType = swFeats
   End If
   
End Function

Sub ProcessFeature(thisFeat As SldWorks.Feature, featsArr() As SldWorks.Feature, typeName As String)
   
   If thisFeat.GetTypeName2() = typeName Then
   
       If (Not featsArr) = -1 Then
           ReDim featsArr(0)
           Set featsArr(0) = thisFeat
       Else
           Dim i As Integer
           
           For i = 0 To UBound(featsArr)
               If swApp.IsSame(featsArr(i), thisFeat) = swObjectEquality.swObjectSame Then
                   Exit Sub
               End If
           Next
           
           ReDim Preserve featsArr(UBound(featsArr) + 1)
           Set featsArr(UBound(featsArr)) = thisFeat
       End If
   
   End If
   
   Dim swSubFeat As SldWorks.Feature
   Set swSubFeat = thisFeat.GetFirstSubFeature
       
   While Not swSubFeat Is Nothing
       ProcessFeature swSubFeat, featsArr, typeName
       Set swSubFeat = swSubFeat.GetNextSubFeature
   Wend
       
End Sub

Sub ExportFlatPattern(part As SldWorks.PartDoc, flatPattern As SldWorks.Feature, outFilePath As String, opts As SheetMetalOptions_e)
   
   Dim swModel As SldWorks.ModelDoc2
   Set swModel = part
   
   Dim error As ErrObject
   Dim hide As Boolean

try_:
   
   On Error GoTo catch_

   If False = swModel.Visible Then
       hide = True
       swModel.Visible = True
   End If
   
   swApp.ActivateDoc3 swModel.GetPathName(), False, swRebuildOnActivation_e.swDontRebuildActiveDoc, 0
   
   swModel.FeatureManager.EnableFeatureTree = False
   swModel.FeatureManager.EnableFeatureTreeWindow = False
   swModel.ActiveView.EnableGraphicsUpdate = False
   
   Dim outDir As String
   outDir = Left(outFilePath, InStrRev(outFilePath, "\\"))
   
   CreateDirectories outDir
   
   Dim modelPath As String
   
   modelPath = part.GetPathName
   
   If modelPath = "" Then
       Err.Raise vbError, "", "Part document must be saved"
   End If
   
   If False <> flatPattern.Select2(False, -1) Then
       If False = part.ExportToDWG2(outFilePath, modelPath, swExportToDWG_e.swExportToDWG_ExportSheetMetal, True, Empty, False, False, opts, Empty) Then
           Err.Raise vbError, "", "Failed to export flat pattern"
       End If
   Else
       Err.Raise vbError, "", "Failed to select flat-pattern"
   End If
   
   GoTo finally_
   
catch_:
   Set error = Err
finally_:

   swModel.FeatureManager.EnableFeatureTree = True
   swModel.FeatureManager.EnableFeatureTreeWindow = True
   swModel.ActiveView.EnableGraphicsUpdate = True
   
   If hide Then
       swApp.CloseDoc swModel.GetTitle
   End If
   
   If Not error Is Nothing Then
       Err.Raise error.Number, error.Source, error.Description, error.HelpFile, error.HelpContext
   End If
   
End Sub

Sub OpenFile(filePath As String)
                   
   If OPEN_APP_PATH = "*" Then
       Shell """" & filePath & """"
   Else
       Shell """" & OPEN_APP_PATH & """" & " " & """" & filePath & """"
   End If
   
End Sub

Sub CreateDirectories(path As String)

   Dim fso As Object
   Set fso = CreateObject("Scripting.FileSystemObject")

   If fso.FolderExists(path) Then
       Exit Sub
   End If

   CreateDirectories fso.GetParentFolderName(path)
   
   fso.CreateFolder path
   
End Sub

Function GetFullPath(model As SldWorks.ModelDoc2, path As String)
   
   GetFullPath = path
       
   If IsPathRelative(path) Then
       
       If Left(path, 1) <> "\\" Then
           path = "\\" & path
       End If
       
       Dim modelPath As String
       Dim modelDir As String
       
       modelPath = model.GetPathName
       
       modelDir = Left(modelPath, InStrRev(modelPath, "\\") - 1)
       
       GetFullPath = modelDir & path
       
   End If
   
End Function

Function IsPathRelative(path As String)
   IsPathRelative = Mid(path, 2, 1) <> ":" And Not IsPathUnc(path)
End Function

Function IsPathUnc(path As String)
   IsPathUnc = Left(path, 2) = "\\\\"
End Function