Michael,
I meant the outer countour (in the sun).
And yes, I got the problem that if the radius is bigger than the actual piece, will not work....
Any idea why the outer countour will not filet? Perhaps some sharp curves, causes MOI to think there is no room to filet properly....

Also, take a look at this file.
I have fileted the different solids OK, except the smaller free form.
Do not have any idea why...

Rudy