Hi Mike,

> I also saw the problem of thight corners and nonplanar
> surfaces, but I don't know how to fix the areas you adressed.

You'll pretty much have to reconstruct the object over again.

There are basically 2 different styles that you could approach it - you would either want to make it more segmented with some more sharp edges in your initial profile or otherwise actually make it more all one single large piece.

Check out Paolo's attached file for the "single piece" method - there you'll see that he's drawn in the side profile in such a way that it is extended more to the left and then the rounded area on the left side is produced by carving off some material from a curve that is flat in the Top view. That basically avoids having an extra edge thrown right in to the middle of where you want to have filleted and anything that simplifies the edge structure of your object (like reduces the number of edges meeting up at a single shared point) can also make things easier for filleting.


> And I thought, even on thight coners, that a
> value of 0.0001 would give at least a very very little fillet.

That would normally be correct if that was the only problem area, but the other problematic juncture areas that I mentioned are also a factor in your case here.

- Michael