Hi seb, so it's just the outside border that you want rounded?
The things you are showing there will be difficult to do as an automated process in any CAD program I think...
Things like sharp small features such as this:
will definitely be problematic, and you'll run into the same kind of problems that you described about if the surface below pieces is too narrow.
Maybe you should try something more like a 1-rail mitered sweep around the outside boundary rather than doing filleting... But actually sweeping will also run into some similar problems from trying to fit a large sized round arc piece around a small tightly bent hook shape.
I don't really see how that's going to get automated very easily, it's difficult for an automatic process to handle all the kind of "running out of room" problems that occur with something like that.
- Michael
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