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
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