I need to create a wrapped sleeve from a single piece of rolled flat plate such that it will form up into a tube but the longitudinal joint will have matching tabs and pockets that will hold the joint together after rolling. The closure of the joint is completed by spot welding the edge of the tabs and pockets.

The sheet metal functionality using a single arc and sheetmetal thickness will not facilitate this geometry as solidworks appears to believe the sheetmetal intersects itself.

I believe I can get a work round to obtain the flat plate developnment for the main body and then add pockets and tabs but I can not get the component to un flatten.

Any suggestions