Hi wim, that's unfortunately a difficult situation for the filleter to handle. The difficult area is in this juncture right here:



The thing that makes that area particularly difficult is that on the upper part the fillet will be trying to go in this direction:



But on the lower part the fillet will be trying to go the opposite way:



So having 2 fillets meet but wanting to go in opposite directions like that makes for a more difficult juncture corner area for the corner patcher to attempt to fill. Also since those pieces are at different angles to one another the fillets there will be of different sizes - they will be arcs of the same radius but one arc will be longer than the other since it needs to traverse a wider angle. So that adds to the difficulty of the corner juncture, and then throw in the other 2 edges as well that are also meeting at that spot too.

So it's a lot more difficult situation for the filleter to handle than what it might seem like initially.

You might need to leave out the upper notched out area initially and try to cut that out later, or maybe try to rework the object so that corner juncture has less edges coming together at that one spot, something like make a more gradual curved transition in the whole shape at that area.

- Michael

Hi Wim, try the attached model - it has a couple of larger surfaces built in those areas and so it has a simplified topology which should be a lot more amenable to filleting.

Most of the time it is good to build the model in the way you were doing and rely on filleting to blend things together, but there are some kinds of cases where the filleter will get confused, that kind of thing with 2 sort of opposite oriented fillets coming together at a single juncture area is one of those.

- Michael

Thanks Michael! that was a clear explanation (again)!

cheers
wim

another solution is to cut the object in half do the vertical line fillets and rejoin
cheers
shayne

Ha cool solution.

Peace,
Rich_Art. ;-)