Hi 3dnutta, that kind of weird holes appearing in the object usually means there was some failure in the trimming part of the fillet, that's where the original object is cut up and has pieces discarded in order to make room for the fillet.

It's difficult to tell what may be going wrong from a screenshot alone - is it possible for you to also post the 3DM model file as a file attachment as well so I can take a look at your actual geometry?

It's probably some kind of bug in filleting, unfortunately there are still quite a few problems with the filleting engine in the geometry library that MoI uses. But it looks like the fillet surface itself may have been generated ok, so it may be possible to salvage the object by extracting the fillet surface, doing an undo, then pasting in the fillet surface and then manually trimming it into place. I can give that a try for you if you post the model.

- Michael