i attached some pics of the netgen mesh for the model i sent. the one with the .08mm fillet. the fillet is so small the mesh is absolutely huge. over 1 million elements. there's no way i could solve that on my laptop. the other thing is, i don't even need to solve it to know the stress would be way too high. you need decent sized fillets to keep the blade from breaking off and killing people. .08mm isn't going to cut it. but the model does mesh, that's the thing that can be a problem. as the model you created shows. that's one of the problems i run into as well. for this particular model a 1mm root fillet that is valid is the goal. i gave up on it a long time ago. i had to go with the version not projected onto cylinders. i think the only thing that might help is recreating the curves that rhino screws up. i'll give that a try next. i'll have to cut them all and rebuild them all. it somehow takes four curves and turns it into two, when you do the projection. the problem is it screws up the le and te.