I've seen this come up a lot in various SolidWorks forums, so I figured I'd go ahead and post a little something about it.
When you need to insert a cut on a bend in sheetmetal, you need to use the Fold and Unfold commands, not the Flatten command. If you use the Flatten command, your cut feature will end up suppressed when you unflatten the part. To unfold a part, simply click on the 'Unfold' button. A dialogue box will pop up requesting a fixed planar face and the bend(s) you want to unfold. Click on a planar face, then the bend(s) you want to unfold. You can also have SW grab all the bends automatically. Once done, hit the check mark and your part will unfold and you'll be able to create your cuts. When you're finished with the cuts, hit the 'Fold' button. A dialogue box will pop up asking for the same stuff as the first one. Simply make the same choices you made when you unfolded the part, hit the check mark and you're done.
I hope this helps!


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