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You could Slice a cone.

Insert Bends should work just as well. I often have to use this legacy tool rather than Convert-to-sheetmetal.

The OP's experience is with a parametric modeler where dimensions are either driving or driven and geometry is either "normal" or construction (think of drawing board).

One of the 2 side Flat Patterns. (I'm not sure if r2006 would allow multi-body sheet metal.) If not, it is a simple process of doing one at a time.http://files.engineering.com/getfile.aspx?folder=e196d18d-77da-4f63-b929-147b54891f8b&file=Side.PNG

Top Flat Patternhttp://files.engineering.com/getfile.aspx?folder=4b15036a-0054-4ae8-8987-54f408d005ad&file=Top.PNG

I always expect to see effort on the basics. In fact it takes no more time or difficulty to sketch correctly. http://files.engineering.com/getfile.aspx?folder=b72c1f23-a7dc-487c-839e-611d4264da3f&file=Fix_Sketch.PNG

This one is pretty easy. First thing I did is "fix" the sketch as it appeared no real effort on getting it constrained. (I didn't change the dimensions.) Then I offset the faces by zero. Thickened them and converted to sheet...

Attach your file here.

First thing I notice is that there are no dimensions in Sketch1. What happened to the dimensions? Second thing I noticed is that Sketch1 is not placed with obvious symmetry about the origin. Third thing I noticed is a fillet in Sketch1 that appears at one "bend" but not on the "symmetrical"...

Not the prettiest threads, but if you fix this problem it looks like it will work. The thread in the Cap is disjointed from the cap along most of its side. (see attached) http://files.engineering.com/getfile.aspx?folder=ab34e311-e7fc-4352-87ff-cba2947e3e3c&file=Threads.PNG

I think PTC might have a direct modeling software that might be better suited to your workflow than a parametric modeler.

Inventor has already told you it is unresolved. How could you see it if Inventor can't "see it"? I am not even sure what you mean. Is there a grayed out node for the part in the assembly component browser? Delete the node.

I should have noted that the orientation of the part (layering) is critically important for best results.

We routinely 3D print threaded holes (down to around M4 or 5 as smallest) (usually larger). You will have to model the threads and allow a bit of extra clearance as the 3D printing process is not particularly precise.

This part of the problem description is confusing as a sphere has only one diameter. Do you have any pictures, *.sld* or urls?

Create a Sketch block. Attach your *.ipt file here.

http://home.pct.edu/~jmather/SkillsUSA%20University.pdf

I use a lot of construction lines - none of them infinite. If you go into the line command and right click you will see construction or create normal line and then there is an icon in upper right corner of screen to toggle it to construction. Project Geometry of the origin axis is, in effect...

This might be interesting. http://files.engineering.com/getfile.aspx?folder=0b185ff8-3f1f-4dee-962b-f5db60a5c91a&file=Geometry.PNG

No dimensions used. AutoCAD 2014.http://files.engineering.com/getfile.aspx?folder=681986b2-12b8-4e56-a321-658f82b468a5&file=Constraints.png