Bad fillet on rotation

Problen Fillet.3dm.zip (7.8 MB)

In the attached I have a 5-bladed propeller. When I try to filled the edges between the hub and the blades a 3", the upper three blades work, one of the lower blades creates a bad fillet, and last one will not fillet at all.

Puzzled why this is the case.

I have gotten this to work by:

  1. Adding one blade to the hub.
  2. Fillet
  3. Subtract a copy of the hub
  4. Rotate +/- 72, _+/144
  5. Create a new hub
  6. Add together

Thanks for you feedback, it seems that the FilletEdge failure is caused by the short distance between the seam of the closed surface and the filleted edge. I provide another method for you reference.

@jessen.ch solution is I think a good one with the current capabilities of fillets in Rhino. Before joining McNeel I worked with marine propellers extensively, and I know how difficult it is to make proper filllets, to the point where I’m actually surprised it works as well as it does for your geometry.

We’ve logged this issue and hope to improve matters going forward.

I could not help but notice that the geometry at the tip seems a bit distorted.

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The short answer is FilletEdge uses a defective algorithm that fails in lots of cases.

You can use FilletSrf to make the fillets. Use the Trim=Yes option in FilletSrf . After making the 5 fillet loops just window select everything and run the Join command.

I’ve noticed that too. The general problem is the networksrf does not follow the curves at the edges. Other surface creation methods turn out worse for me.
![ViewCapture20250503_084826|690x440](upload://i77QYGR3fJVoQ78VQfzsXHOWacQ.jpe

This is what I get by filleting one blade, subtracting the hub, rotating 4 times, adding a new hub:

You might try a Loft for a smoother surface.
I extracted curves from your surface and straightened them a bit.

propX.3dm (4.1 MB)

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thx, what did you loft among?

The red curves are the curves I used for the loft. You have to select the curves manually in the order they belong on the surface. I started with the lowest curve and went upward ending with the point at the tip.

The curves were extracted Isocurves from one vane surface you posted. I edited the top two curves to get rid of the bulge in your vane surface.

In the image below the red curves are the curves to loft and the blue curve is a silhouette of the original vane.