Hi d3, the filleting mechanism in the geometry library that MoI uses is just not as sophisticated as the ones in the things like SolidWorks, SolidEdge, etc...
There are several kinds of things going on in your case here that it won't handle.
For example, the edge based filleter will not know that it should try to build a fillet between these 2 faces that do not actually share an edge:
Also it will have difficulty with things like this face being totally consumed and disappearing:
I'd recommend exporting cases like this to a different solid modeling program like SolidWorks, etc... which are able to deal with these kinds of "minimal clearance" type issues better.
MoI's one will work pretty good if it has enough space to create the fillets without needing to run over other faces though.
Otherwise if you do want to make it in MoI you would instead need to use some surface modeling tools to build it, something like trim away some areas and then build a sweep in there instead of trying to use fillet. Let me know if you want to try that and I will try to help you with it, but really if you have another solid modeling system available to you, it's easiest to export over to it and do the fillet there.
ViaCAD ( http://www.punchcad.com/products/viacad2d3d.htm) is a low cost solid modeling program which can be helpful for this purpose if you want something inexpensive to help with filleting cases that MoI does not handle.
Also SpaceClaim can be good for this as well, I think you can now copy and paste objects back and forth with SpaceClaim.
- Michael
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