Novice requiring assistance with fillet issues

Hi Rhino Experts!

Any advice, solutions or tips would be very much appreciated because my deadline’s apporaching very soon… Thanks!

earlier i was working on this project and faced this issue where as when i tried to fillet this part:


it will always produce this error where as it’ll break the shape when making it all 0.25 radius as shown below:

Here’s my rhino file:
Model 1.stl (9.4 MB)

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the file you uploaded is an stl file format, do you have the original Rhino .3dm file ?

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ah sry i uploaded the wrong format
Model 1.zip (10.9 MB)

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the edge marked with a dot (x) is not tangent.
(you can check with _edgecontinuity )
to extend the gray fillet-Surface (and close the gab/hole), the fillet has to connect between the 2 blue surfaces.
you can build the red fillet surface with _filletSrf
then you have to manually trim and join.

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I see… from what i understand, is that the current shapes that i’ve created, it cant fillet due to lack of space…? so i’ll just have to manually trim and join for each and every one of them that breaks?

i heard i can create the fillet with blending edges instead… though im not sure how it works…

it s not a question of space, but of the geometric conditions at this corner.
The surface/patch layout that solves this corner can not be generated automatically by filletEdge.
And as most cases where filletEdge fails, you can manually build surfaces with filletSrf. (sometimes also revolve, extrudeCrv, sweep1/2). Then trim and join.

maybe check some tutorials - for example

or check this forum for fillet-Problems that got solved.

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You’re making it way more complex than it needs to be. The thickened parts could be an offset of the base surface, this way you don’t end up with the tangency issues that @Tom_P pointed out.

What’s the end goal of this object? Are you building this for manufacturing, rendering, 3dprinting?

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The end goal for this project as of now, is for a mass manufacturing after 3D printing and molding to see how it goes.

i actually have no clue about what you just mentioned above… because i’ve only been using rhino for few months

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First of all you need to make sure that the curves you are using to trim the surfaces need to be clean

The method I would suggest to try out is:

See attached example workflow
example_workflow.3dm (5.4 MB)

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ooh i see… so thats what i was messing up at… my surfaces are all quite messy, nowonder when i tried pulling that border out, it started to break some of the original shape.

lemme try applying this to my model, maybe that’s the key to solving my difficulties and get back to this. Thanks!

Wow, it actually solved most of my difficulties! Thanks!