Hi Pilou, your shape here goes through a kind of sudden dip in a quite small area here:
It's not good for filleting for a surface to have such a tight fold in such a small area like that. It also may be possible that the middle area is basically intersecting with the bottom plane, making a self-intersecting type surface which also can generally confuse intersection mechanisms.
You'd need to get that tip area to be more regularly formed in order for a sensitive operation like fillet to really have a chance.
One part of filleting can involve extensions of the fillet pieces before intersecting them with other things, if there is some problem in the intersection it's possible to get fillet segments that shoot off further than you would expect.
- Michael
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