Any insights on why this free form straight workshop rebar can not be exploded?

Hello Miguel

Could you please send us your project files within the forum or via the technical support: Revit → Help → Support Assistant (support@sofistik.com).

In the meantime you can try to leave the instruction shops bended and then explode them. Perhaps this workflow works.

Best regards
Frederik Höller
Your SOFiSTiK Support Team