Hi Tom,

> So is it necessary to follow a certain routine to build up a model
> to be able to fillet its edges ?

It depends on the particular situation, basically there are some kinds of edge arrangements that the filleter has difficulty with.


> My way was to start with a frame of curves from which I created the surfaces which I
> multiplied with array and then merged with boole > union - wtong ? (see attachment).

Well not necessarily wrong, but it is generally better to work more with solids from the start, like use some curves to construct an initial solid and then use boolean difference to cut away chunks of that, rather than doing a "patch by patch" type of fill in of a wireframe like you're describing.

Do you come from a polygon modeling background? I've noticed that there is a tendency for polygon modelers to try and do that "patch by patch" approach. There are some tips about building extended pieces and using cutting operations more in the discussions here:
http://moi3d.com/forum/index.php?webtag=MOI&msg=4865.2

- Michael