I find it mind-boggling that Rhino V8 still can’t deal with basic fillets.
Heres is the Rhino / Fusion 360 comparison of filleting the top face of this solid :
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I’m assuming you filleted the top face with the same radius as the fillets on the vertical corners correct?
@menno is the new developer that has started work on Fillets that will hopefully address cases like that eventually.
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Send us a 3dm please, that will help pinpointing the problem.
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These issues occur exactly for the reason you mentioned. Applying same radius as in existing adjacent fillets.
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@menno here’s an example based on that image. In one go it works, in two steps if fails:
chanel.3dm (1.3 MB)
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This longstanding bug also impairs Rhino’s FiletSrf command.
If you want to see how this should work in Rhino you can use this script which can be found here.
The script is designed to work with tangent surfaces so I modified Gijs’ model to make all the surfaces that are being filleted tangent. Tangent_Surfaces.3dm (226.8 KB)
The script works the same as the FilletSrf command. You pick on two surfaces and it will create the fillet between them, but then it also finds all the other tangent fillets that connect to the first fillet and then does the trimming and joining. The fillet radius that will make the spherical corners is 2mm.
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Yes, I had that audacity.
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More crappy fillets :
Just wanted to fillet 4 edges (R=5)
2433_MOD_240716_Support Jauge Z.3dm (401.6 KB)
Here is the model, properly filleted by Fusion 360 :
2433_MOD_240716_Support Jauge Z v1.step (59.9 KB)
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Curious, what’s the command you’re using to get the piece of crap result?
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Hi Anon, it’s _FilletEdge
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Some more.
240717_IMG_More fillet failure.3dm (399.5 KB)
Meanwhile, in Fusion 360…
…how it dealt with the top ridge :
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What Fusion did is perfectly fine.
I don’t need to do Class A modeling for this : it’s just a lousy cap I’m 3D printing.
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If it is just for 3D printing, you can also skip the boolean union and design the parts so they overlap slightly, then export one *.stl with two disjoint meshes…
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I know, but this is not the point.
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so looking at the these pictures it tells me that Fusion 360 is the package that solves it like crap without you knowing it, With Rhino you sure can solve it but it depend on how you build your initial surfaces and volumes, and the order when to apply union and or radii. If I get these sticking out surfaces after I applied radii, I know I have to redefined the build on a few details to correct it. Rhino can also easily do the “support jauge Z” without any problem along as you build your base volume correctly. I used your file and corrected it in 2 minutes… the limitation is not in the software…
now do that for 50 parts 
The point is that these things should work, and that people expect this to work. Sure you can fix it manually or with the right modeling strategy, but that requires deeper knowledge and thinking ahead.
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Would you mind elaborating ?
I did it in a straightforward, easy way.
Maybe you have a much more involved, intricate and nerdy way of merging a dumb plate with a stupid cylinder…
Let’s see.