Hi Niko, well the error is pretty small in size, do you actually need it cleared up?
If you just want the boolean to work, the solution I posted previously will work (scale down, join, scale up) for getting it into a solid and getting the boolean to finish.
If you need a better fillet in that spot, do you have the original unfilleted shape that you could post? Possibly doing a scale UP first before doing the fillet could actually help with the fillet, it may make the fillet be denser and more accurate and possibly intersect better.
Another possibility for fillet quality is to try using a surface/surface fillet instead of the edge-based filleting. To do surface/surface filleting you break things apart into individual surfaces and then just select 2 surfaces at a time for fillet construction. You may need to do some manual trimming for this method.
- Michael
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