I’ve noticed lots of filleting problems (naked edges, or fillets that show up, but won’t trim the prior geometry) and failures when a surface has either or both conditions:
A) a lot of UV’s (often resulting from FlowAlongSrf commands of a simple planar surface).
B) kinks in the surface
When I rebuild these high UV surfaces to lower UV’s, I tend to have more success filleting a resulting solid.
The questions I have are if Rhino rebuilds a surface with a lot of UV’s (in my case 26U, 55V from a previously planar surface):
A. Why are the UV’s so high? (is this a tolerance issue?)
B. Like doing the limbo, how low should one go, or how low is too low, when rebuilding UV’s?
As for kinks, well… is there any hope other than manual repair after the fact?
You can download an example of the problem rhino file here (2.2 meg)
Many thanks for any insights!