Hi Chris, I'm taking a look at it and I don't see anything really obviously wrong with it.
The one issue that you may be running into is a fair discrepancy in scale - your main object being about 6.8 units across, trying to then put a fillet of 0.008 units on that is a difference in scale of 850 times between those features of the model.
A difference in scale approaching that kind of magnitude can cause some difficulties - like the edge tolerance for the boolean was probably done at 0.001 units and that may not have been tight enough for the 0.008 fillet to get a good result on top of that.
You might try modeling something like this starting at a bit larger scale, like 10x its current size and then scale the final result down. That may help gain some extra accuracy because things like the 0.001 unit accuracy that was done with the boolean union at that 10x larger size will have stuff calculated a bit tighter.
The only other thing I noticed was a little bit of wiggling in some of the shapes, like here things are a little wavy (subtle but a bit of undulation in here):
It could be better if these shapes were actually more segmented, with some more plain straight line pieces in there.
But I'm not really sure what is exactly going wrong though.
Do you happen to have a version of this model before doing the boolean union?
- Michael
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