Simple shape wingnut and FilletEdge small enough to suit yet fails

I did want 0.05 but even opting for 0.02 sees gaps and so on , what is wrong here ?
wingnut.3dm (170.9 KB)

I wanted 0.05 for the wings down onto the top and at the sides and a smaller radius elsewhere but FilletEdge allows for only one choice, or is there a way of having multiple radii in one go, I find that when filleting ANY OBJECT in rhino, the result from one radius disallows the next filleting given what it produces, its as if the ‘team working on the 0.5 need to liaise with those on the 0.02 and between them sort out where the two meet at the same moment’ imagining a litle workforce there with masks and steel hats on !


Hi @Steve1
Your top and bottom surfaces are a mish-mash of large and small surfaces. Either run MergeAllFaces (or whatever it was called in V5… if the command even existed back then) or extract/delete the faces and use Cap to create new faces - then try 0.02 - should work (does in V7). I’m quite sure this has been explained to you before. If you want to have 0.05 fillets, you need to either make the protrusion on the wings larger or manually construct the fillets.
HTH, Jakob

ran MergeAllFaces and then 0.02 worked,.

I then do the MergeAllFaces and 0.02 on my origonal from which that was exported, and again it works, I try for 0.03 it fails, so I undo and redo the 0.02 AND IT NOW FAILS. Check I havent undone MergeAllFaces, no that is still the last command, so try again and 0.02 fails,

what the heck ? typical my luck. So I will export from the forum post one and import it, but why when they are the same, I do wonder if my project file is corrupted, what with macros altering geometry, and dashed circles appearing.

wish there was a way of using 2 or 3 different radii in one shot on it and other objects.

I just dont have time to try and construct 0.05 fillets along joint of wing to body at the mo.

5 hrs getting to grips with layout making one plan, and success apart from pesky margins too wide in default layout,
another 20 to do.


After all these years in Rhino, you should know by now that Rhino in general does not run fillets over edges. Use manual FilletSrf (with extend, join, trim)
or use SolidWorks or any other solid modeler:

It doesn’t take very long to do with FilletSrf
In the enclosed file first make the cyan fillets with trim=yes and extend=yes. Then make the orange fillets with trim=no and extend=no. Then join the orange and trim and join to the rest.
wingnutx.3dm (265.8 KB)

It would take even less time if Mcneel would automate the making of the orange fillets so that they are all made at once.

well I have followed that as much as I can, see attached.
storyboard here,

I cannot get the orange to go all the way, to even get the smaller bits took some clicking on grey and on nearby cyan to sometimes see bits form, although it was not obvious to me they would even want to know about each other, gaps remained I simply couldnt fill by clicking on any more grey and blue or grey and grey.
Selected all orange, joined, then trim tool and deleted the redundant grey parts, cannot get the blues though due to the gaps.
I gave it my best shot, though 1hr of trying, time I just didnt have, means 4am end work now, for a wingnut.
To be able to stick ones hand in air and a tutor says do this then this and its done would be good.

I just cant spend any more time on it now, 4am is not good. and 15 mins to do the storyboard so you can see what I did.

files attached

So why did it fail me, why didnt the oranges all join up, there werent any surfaces there for filleting it seemed.
wingnut 001 FilletSrf results orange trim grey.3dm (487.9 KB)
wingnut 001 FilletSrf results orange.3dm (428.3 KB)


Hello- you just need to create the fillets, as between the two blue surfaces here - is that what you are asking?


Steve, here is a short video:

wingnut_filletSrf.3dm (330.9 KB)

Hi Pascal,
yes, make up the gaps so all orange fillets join up and will trim blue.

Gijs, THATS FANTASTIC, to see a vid is the ultimate, search for the challice, says so much more.

So I should have run fillet surf from blue to blue, as well as what i did of grey to blue, idid all the cobinations I could think of.

What I forgot was also FilletSrf will bridge gaps, doesnt always need surfaces to touch, am I riight ?

then the trimming and mirroring, didnt glean that from the text.


Yep, sometimes you need to add fillets between previously made fillets.


Hi Pascal,
as per my reply but just which missed yours, I didnt realise one can fillet between fillets that dont even touch each other.
Trouble is if one tries it on something else and it doesnt work as hoped for, then what.

To have a variety of test pieces in increasing complexity to hone ones skills on with Filleting and chamfering, would be good.

The other day there was I trying to filletSrf and you said best use FilletEdge, so this time I used FilletEdge as FilletSrf would not let me select all the adjoining surfaces, doing parts and one cannot see the result that well, and this time filletSrf was the way.

Its knowing horses for courses.


You did quite well . You are doing significantly better than McNeel and his hapless band of developers have done in the last 20 years…

There are two things you need to understand that are causing the gaps in the fillet chain. First the FilletSrf command will fail if you try to fillet where one of the surfaces is the same sized fillet. That is not your fault its McNeel’s fault but good luck trying to get McNeel to make improvements to the FilletSrf command to fix that bug.

To deal with the problem that FilletSrf can’t make a fillet when one of the surfaces that you click on is the same size you either need to make that fillet with a bigger radius or learn to manually make the .05" spherical fillet that is required. In the example you offered I just made the cyan fillets that the fillets in the main fillet loop crosses over a bit larger - that eliminates any problem with FilletSrf not being able to handle running into a surface with the same radius that it can’t handle.

The other problem is that you just missed some surfaces. That is easy to do after all you are not a computer. If Mcneel .and his incompetent developers can’t understand how it works why should the user be expected to understand it? As you proceed around making that fillet loop, all you have to do to figure out where the next fillet goes is look at the corners of the last fillet you made - the two surfaces that you find there (the two surfaces you have not already used) are the surfaces that you pick next. If you follow that simple recipe you will make all the fillets that go all the way aroundt untill you find yourself back where you started with the first fillet in the loop.

you need to learn to use the symmetry of the part to your advantage.
In the model I sent all you needed to do to finish the part was to use Mirror command to mirror the fillets from one side to the other and then trim and join to complete your wingnut.