@Michael
>>Do you think it would be better if I removed the constant distance option entirely rather than having it in its current state?

hehehe ---> black question
I can remember problem with champfer, option two distance (that was before v1)
It took long time until it worked.
With fillet will certainly ok, sooner or later.

Little idea, moving stitched edge outside critical region, can help for filleting or edge split.
Is this possible ?
See file....

@Danny
>>We've probably all come across these types of limitations, not only with MoI, it happens in all software, even in cad software that costs 10's of thousands of dollars,

These programs do not interest me, moi3D will be even better.

>>we simply avoid them, before we commit to a boolean operation we just have to think a few steps ahead and think will the seam get in the way.

and if we edit a file from foreign hand ?

>>What I figured with the 'Merge' command is that if you try an merge multiple sections of segmented edges it screws up the spherical surfaces, but if you do a section at a time it >>works fine, so you merge the segmented edges of one sphere section at a time.

Hehe, i love one click, not a hundred.

-regards