Another thing that makes what you're asking for about automatically doing the "maximum radius" fillet is that it's not unusual for the fillet to be kind of a bit mangled or poorly formed when you're trying to generate one with a radius that is right close around the neighborhood of where it starts to cross over itself. It's easy for the cross sections of the fillet surface to start to pinch together as they get close to crossing over each other and so shooting for that exact maximum spot is probably going to have bad side effects.

Something like ten percent less than the maximum or something similar to that would probably be a better target...

Anyway that's another complicating factor in what you are describing.

- Michael

Thank you for you replies and sorry for the images snafu.

I am not really looking to have the "maximum" radius automatically applied, but I'm looking for a a way to fillet these edges that is faster than Rhino, which is very time consuming for this task. I would need to prepare many of these each day, and I have to actually produce these afterwards so I don't have much time to deal with the fillet.
I wanted to know if MoI can do this faster and better than Rhino

I've uploaded the images this time:

1. This is the kind of shape I work with (letter combinations). I import it from Illustrator


2. From that I extrude a solid, but I want it to have round edges.


3. This image shows where the problem is. Even if I correct each radius in the preview the result is pretty bad.


4. This image shows another problem in Rhino

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

Thanks for your reply.

Yes I was asking just in case, but I guess MoI and Rhino handle filetting pretty much in the same way.

I'm trying to see if I could have a Rhino developer make a script for this, but don't have high hopes...

Thanks anyway