Hi Don, your model has a little misalignment in it which seems to have created a kind of micro shelf in this area here:



Zooming in there, there is a little teeny tiny edge that's only about 0.001 units long in there:



That's probably going to be what's hosing the filleting from working, although also the upper part of where you want to fillet where the surfaces become tangent to one another may be another problem area, since that's kind of a special zone where fillets degenerate down to nothing.

But I'd try slicing off the bottom by just a bit with a line to get a cleaner bottom face structure and that may help.

- Michael

Hi Don, so after slicing off the bottom to get a clean end (see attached model), it seems to now fillet ok, shown here with a radius of 0.3 units:



- Michael

Thanks Michael,

I had sliced the bottom off, but I guess I didn't make it high enough.

Operator error again!

No problem Don - that's a good example of why it's helpful to be able to examine a model file instead of just a screenshot. It's difficult to see specific things about the model's structure like if it has any little shelfs or micro edges just from a screenshot alone.

- Michael

Hi Michael (or Don),

I'd like to know how you did the "rounding" shown on the jpg that is not in the 3dm if possible?

Thanks,
Felix

If you are referring to the cap profile, I just laid out a number of tangent circles and trimmed, then offset and joined.

Don,

I was referring to what looks like a variable fillet that you can see on the screenshot Michael provided and that is not in is 3dm file. I've made a screenshot of is 3dm file so you don't have to download it.

Thanks,
Felix

I just made sure to cut the bottom up a bit to ensure the segment had a flat bottom face. Then the fillet tool worked just fine.

Hi Felix,

> I was referring to what looks like a variable fillet that
> you can see on the screenshot Michael provided and
> that is not in is 3dm file.

That was actually just a regular constant radius fillet - to do that download the model Bottle Cap Segment2.3dm that I posted above, then make an edge selection like this:



Then run Construct > Fillet to round those edges off - here I used a radius of 0.3:



That's normal that a constant radius fillet can grow or shrink in size in areas where surfaces change their slope to one another. In areas where the surfaces are coming close to being tangent only a small sized fillet of the given radius will fit in there, and a larger span is needed when the slope between them increases.

Here's an example with curves - note the size required to make a tangent arc in each of these cases - the span of the arc increases or decreases depending on the slope between the lines. That's not variable radius though - each of those arcs comes from a circle of the same radius.




A variable radius fillet means to adjust the radius size as another additional separate thing.

- Michael

Hi Michael and Don,

I did exactly what you suggested Michael and on my first try it didn't work at all. I think I know why, when Moi open and you load in the file, the fillet command as no default fillet radius and I did put in 0.3 as suggested but I must have forgotten to press enter or something like that. Now it works fine. Sometime I wonder if I'm not loosing it as I get older, I make way to many mistake like that for my taste. I apologise for being so...

Sorry,
Felix

Ed:

Great render.

<< I made a custom material using a flat photo of a real bottle cap as a label (decal) applied to the model, rendered in KeyShot.>>

What software did you use to apply the label?

YHWH_777 - The label is made from a straight on photo of an actual Pepsi bottle cap, copied using a round selection tool, and saved as a transparent png. The png photo is applied as a label (decal) within KeyShot's material editor. KeyShot has the ability to load images, resize and position them over the model. Great for applying graphics to cars or labels to wine bottles :) The reflections in the Pepsi bottle cap are coming from the HDRI environment I selected in KeyShot.

Ed