Fillet failed

[wim (Wim Dekeyser)]

Wasn’t that explained here:

Fillet problem with boolean

Here is a file showing how I would approach this: Trimmed_Tab.3dm (339.2 KB) First I would make the bent tab part by extruding its profile (cyan). You can extract and delete the surface (green) where it will connect to the main body (black). Second, add the pieces for the side clearance (red) Then you can select all four parts (2 red, 1 cyan, and 1 black) and trim away all the pieces that you don’t want. Make sure you trim away all the parts that need to be trimmed. There is an internal p…

If you have specific problems with any of these steps then try to identify which step you find difficult.