Hi Leonard,

> Scaling up: my metal thickness is 1/32", or 0.031". Are you suggesting
> I scale up 100 times? If I scale that up 100 times my metal thickness
> will be 3.125" thick. Am I right on that?

Yup, but the scale up is just a temporary measure to avoid approaching too close to the 0.001 tolerance value for the fillet calculation.

Once the fillet has been calculated on the larger scaled object, you can then scale that filleted version back down to its original size again.


> Do I change those settngs back prior to exporting?

Nope, that is not necessary - those settings only have an effect on the display of the model in the viewport during normal modeling.

When you export that calculates a separate mesh from that, which is instead controlled by the "Meshing options" dialog that is displayed during the export. The export mesher does quite a bit more work to try and avoid making an unnecessarily dense mesh.

If you switch back at some point later on to working on a more simple model instead of a denser one, then you may want to switch the settings back at that point in time to get the smoother display which looks nicer on the screen.

- Michael