Sorry, but you said “design proposals”. Subdiv is absolutely fine for that.
But we’re getting off-topic now.
Let’s complain about the filleting in Rhino a bit more! 
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Oh my god, I got upset with Rhino today, because I had a pretty simple perforated surface and was curious if I could actually fillet it in Rhino or have to move to Solidworks, and of course I had to move to Solidworks, because Rhino couldn’t handle even G1 filleting over a teeny-tiny little face that’s coplanar with its adjacent surface:
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tried MergeAllFaces before filleting?
Neat, that fixed that particular problem, but I just tried a few more and still no dice. Trim and join was set to yes here, but still I got this:
EDIT: Another example of two very simple fillets meeting up, and again Rhino doesn’t manage to trim and join them…
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Ok, I think this is a record for the simplest fillet fail in Rhino for me so far:
Why on earth did it fail here?
blend-edge-fail.3dm (70.9 KB)
EDIT: Ok, I now separated the top (rounded) from the bottom surfaces in the above image and joined them separately… and still BlendEdge fails on both the top and the bottom surface pairs… what am I missing here? Rhino can’t possibly be this finnicky…
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Piling on with another example here, in the vain hope that fillets will be improved in the future:
There was no reason for the above example to fail. Manually duplicating the surrounding edges and then trimming produced a result that joined with no issues.
radiusfail.3dm (136.1 KB)
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Hello - if you are filleting at radius 3, that is a larger radius than the upper curved surfaces have , ~2.66. Fillet at something smaller than 2.66 and it should work better.
-Pascal
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That one looks to me like it ought to work - my guess is the problem is due to the seam in the middle at both ends of the fillet - if I replace the flat side with a single plane, it does a better job trimming off that end of the fillet. In any case, one for the pile, thanks for the example.
Hmm - on further digging, I see that there are edges in that area of the polysurface are out of tolerance… let me see… Nope fixing that does not help…
https://mcneel.myjetbrains.com/youtrack/issue/RH-56879
-Pascal
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Thanks for opening an issue!
Perhaps if I provide an example for whenever the fillet fails, in a decade or so Rhino might get great filleting. 
Also, regarding that radius limit… in theory… shouldn’t a G2 chordal fillet be able to ignore all that (especially since that isn’t even called a fillet in rhino, but a BlendEdge)? I ask, because even then I can’t get Rhino to produce clean surfaces for me.
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I encountered this one today, and as I can’t think of a simpler overlapping fillet example and this really should work, I’ll post it here:
overlappingfillet.3dm (103.2 KB)
(There’s architecture plugins and jewelry plugins that cost more than even Rhino itself… but there’s no product design plugins that handle filleting and unfilleting better than Rhino? Market size isn’t large enough to sustain a developer for this?)
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Who cares about product and transportation designers ; )
Hello - use FilletSrf here. At the moment, that is what is available - Edge filleting does not jump over ‘consumed’ faces.
-Pascal
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The “Fillet curves” command ("! _Fillet") could handle such cases easily. Simply run the command and click on the existing 6 mm radius surface and the vertical wall, and build the desired 7 mm arc. That will allow you to extrude it and make the fillet you want.
Stumbled over the “at the moment…” part of your comment.
Are there any serious plans to overcome this limitation (given that this has been lamented over by users for ages)?
Cheers, Norbert
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Hi Norbert - yeah, I know… and I do ot have anything encouraging to tell you I’m afraid.
-Pascal
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Don’t worry, I know how to work my way around it.
Your comment just made me curious.
There are more annoying, smaller bugs in the blendedge/fillet edge commands that needs to be taken care of…
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Ok, time for some praise as well, because I was pleasantly surprised by this just now:
Rhino extended the small blend surfaces all by itself and managed to keep them closed! 
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Sometimes I think this topic should be renamed “why does Rhino have lots of issues filleting simple surfaces”? 
Green and blue are tangent. Rhino’s FilletEdge attempts to do this in a single surface and fails. Why can’t it just give up and split it into two surfaces, saving us all from a lot of manual work AND getting cleaner fillet surfaces at the same time?
EDIT: An hour later, sort of similar issue… the crazy thing is that these are not advanced fillets! It’s super simple stuff, and Rhino fails (I had to take the body into a different CAD package, and there it was just one click, as it should be)…
(Oh, and the Y-fillet in the bottom left corner there? That’s also a different CAD package, because of course Rhino couldn’t do that either. I’ve said preciously that I’d pay double the price of Rhino for an unfillet command, and I’ll say the same for actual, good filleting capabilities.)
EDIT: This one was new to me…
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