Hello! 

First post so I apologize for any rookie mistakes. 

I am going insane trying to solve this issue. The part is giving me the intersect error and I can't find any issues with the part.

I have tried/checked the following:

1. Reduce flange and base flange size my a small amount (.1mm) and large amount
2. uncheck the corner treatment box on the flat pattern
3. close, open, rebuild countless times

Any suggestions are appreciated because I'm all out of ideas.