Hi Keith,

>>1. How it looked in Moi with fillet radius set at 0.4
>>2. How it looked when converted to .obj

I am not sure if it related to the fact that MoI will allow an overlap when creating a fillet on a cylinder (that is too big) as I have not seen the problem you mention.
Care is needed when making fillet on a cylinder as it is not allows noticeable when the error I mention does happen.

Simple example:

A cylinder of 3 rad will fillet correctly up to a fillet of R2.99,... a fillet of 3 will fail, but, fillets above that (to a certain size) will be created incorrectly with a surface overlap at the top of the fillet. It is not always obvious, but to show the problem, I have a cylinder of rad 3 with an end fillet of 4:-



- manz