Struggling to fillet corners of polysurface

Hi all, and thanks in advance for your help!

I am pretty new to rhino7, I have completed the basic training supplied with the software (really good, very impressed McNeel!) but I am now having a few problems with my model.

I have two halves of the model that have the same shape (on the part that is giving me problems, there are some differences in another area that should not affect it) however when the two halves were created one was extruded to full thickness in a single operation leaving the ‘top’ face as a single surface and the other was extruded to half thickness and then another curve added on each ‘side’ face of the polysurface and they were extruded to give the part the correct thickness.

This has resulted in the ‘top’ face being made up of three rows of surfaces one of half the total width in the center and two of quarter total width either side.

When I have then tried to fillet the edges of this polysurface I can not achieve the same fillet radii as the bottom part as the fillet tool seems to not like where the surfaces in the polysurface meet.

I have exploded the polysurface into its individual surfaces but I can not seem to forge them back together into one surface the same as the single surface of the same geometry on the bottom part (before I filleted the bottom part).

In short, my questions are:

Is there something in the fillet tool that I am missing that is causing me to have this problem?

How does one permanently ‘weld’ two surfaces together to create a single new surface, not a polysurface?

Thanks again.

John

Pipe Cutter 001.3dm (1.1 MB)

Apologies, I should have added that the additional extruded pieces were joined to the original extrusion by boolean union.

John

You can join the surfaces with the Join command. It creates one closed polysurface.

Your part has a few small surfaces at the front, those will make it challenging to create nice fillets.

Which edges do you want to fillet? What radius?

I’d create an arc segment instead of these two small segments and then extrude

Check this example: 21_03_04_fillet.3dm (881.5 KB)

Hi Martin, thanks for your help.

I managed to find a sort of workaround by exploding the piece and deleting the ‘top’ surfaces and extruding a new surface between the two side faces, this has then let me fillet the part the same as the bottom half.

I tried the join command but although it seems to join the surfaces into one polysurface there is some apparent memory of the original surfaces (as demonstrated if I then explode the part it will return to the collection of original surfaces).

It seems that it is this ‘memory’ that is causing the fillet tool to not allow me the same radii as the bottom part.

Is there a way to recreate this same outcome without deleting surfaces and recreating them?

Thanks again

Another solution would be to fillet the full piece and then cut into parts

There is no reason to try piece together all the divided surfaces.
You have all the surfaces as you want them on the other side. Use the mirror command to get the surfaces you want.

In the enclosed file I extracted the surfaces that were unique to the side you are building (they are the orange surfaces) I deleted the rest of that side. I then mirrored the surfaces you want from the other side (the cyan and red surfaces) and then trimmed. The cyan parts are good to go and can be joined to the orange surfaces. The two red surfaces need to be untrimmed and then re-trimmed and then the whole thing can be joined into a closed polysurface.
pipe-cutterx.3dm (1014.8 KB)

Hi Jim, thanks for your reply.

I agree, there is no reason to try and change them into a single surface as far as I can see, the only reason I wanted to is that the fillet command worked on the polysurface that was made from 2 surfaces but it wouldn’t work on the polysurface that was made up from the many surfaces.

I was not sure if it was the way that I was trying to construct the part was unorthodox and that was causing the problem or if my workflow was sound and I just needed to ‘simplify’ the polysurface so the fillet command would not be messed up?

Thanks again