Could someone tell me why the fillet here is failing?
This doesn’t seem to be about corner radius.
How can I solve this? Is it due to a defect in the original curve? If so, how can I avoid this problem when making the original curve??
At spot where the fillet fails there is a break in tangency between the original curves. Explode those curves and use Match curve to fix the problem. Once that’s done it fillets just fine. It was hard to spot with Curvature analysis but 90% of time thats the cause.