Hi Steve,

> I was under the impression that rounding edges
> actually helped filleting.

If it's a tight bend that's basically resembling a fillet, it's usually best to actually let it be filleted as well.

If it's quite a bit broader of a bend than the fillet radius that you want then it's fine, but tight bends make things difficult for the filleter because basically a fillet has some similar qualities to an offset that it wants the fillet to hang off of the surfaces at a particular offset distance of the radius that is being used.

When you have something hanging off of a curve and the thing is larger than the curvature of the bend in the curve it causes this kind of bunching/self-intersecting type effect which then makes things difficult for the filleter in those areas:



- Michael