The fillet edge is keep creating a gap instead of creating a smooth intersection. Can someone pls help me?
myHammer.3dm (835.5 KB)
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Hi Baris - this is because, in your particular example, there is a seam in the hammer head surface that happens to be closer to the edge being filleted than the radius:
Rhinoās great weakness in filleting edges is that it cannot find faces that are not on the edge being filleted - it cannot ājumpā over to an unconnected face.
In this case, use FilletSrf , twice, with Extend = No.
Youāll then need to trim and re-assemble the part.
A sort of geeky way out, if you want to re-make that part is to set UseExtrusions to make polysurfaces rather than extrusion objects, and when you extrude using ExtrudeCrv, set SplitAtTangents=No - then the only seam will be from the curve seam, which is not at that awkward location.
Iād just use FilletSrf on what you have, good to get that process worked out, youāll need it again.
-Pascal
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Itās odd that we seem to know what the weakness are, but no way to get around it automaticallyā¦ 
Moving seams and trimming things manually to help Rhino, is fine I guess. Probably some crazy NURBS maths problem or somethingā¦
My approach would be to eliminate the problematic edge in cases similar to this.
myHammer_emod.3dm (3.3 MB)
I basically networked them two srfs together as accurately to the originals as reasonably possible, then joined everything water-tight, and filleted to 2.5mm radiusā¦
Too bad Rhino couldnāt do that automatically. I should probably make a Eto.button or somem. āmerge srfsā seems primitive.
Maybe I shouldnāt have networked those srfs, but sometimes design intent needs to be compromisedā¦or questioned. Like why was the edge there? And should it be there?
Thereās other parts of this āhammerā where there probably should be some edges, in order to clean up some curvature isolations, but I donāt want to be too critical 
I probably already moved one that was supposed to be there 
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thx for your help
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thx you for helping me
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hi Pascal i tried your Method which looks really simple, but using a Mac is there maybe a bug? i could not get the Fillets to intersect with the underlying surfaces, so trimming and joining is by all means not possible. Or did i miss something?
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@baris1
you can also use pipe on the edge, then trim off the surfaces and use BlendSrf with option chain edge.
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Hello - should work but use the fillet edges to trim not the fillet surfaces - then Trim does not have to worry about the barely-touching fillets leaving gaps in the intersection curves.
-Pascal
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hm that even worked and joined in the endā¦ strange.
remember the crv trick for trimā¦
run the trim command, then type crv in the command line and hit enterā¦ this allows surface edges being selected as trim input objects.
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i use that trick alot