Hi Skwerm,

Here's how I would resolve the problem, but others might probably come with better solutions.
My guess is that the sphere seams will create trouble for the boolean subtraction.



So I rebuild the groove, using half sphere (but taking care to avoid seams)



I have attached the .3dm file too (without the fillet operation)

-- EDIT

Ok, looks like the groove need to be build a little bit more carefully, because while the fillet operation works, it generates naked edges :S

Hi Skwerm,

Better result using a little different method to build the groove, using the deform tool.
But the idea is the same, avoiding sphere seams to help the fillet operation after the subtracting boolean.

Looked through help for "Deform Tool" and didn't find it.

I'm not upgraded to v3 yet. Is that a new tool?

Thanks for the response!

I've tried a number of ways to get a hemisphere without a seam but can't create one. How did you do it?

--EDIT-- Okay, by boolean subtracting a cube aligned with the sphere's original seam worked. Is there a better way?

Hey skwerm,
Although you don't have the newer V3 and deform-flow, I thought I would show it anyway.......

Oooo! Snazzy!

I have been planning to upgrade to v3. I guess now I've got a good reason!

Thanks for the video.

Cheers!

Hi Skwerm, were you able to get your piece finished up how you need?

Something in the filleting system seems to be getting pretty confused in your original case. One way to get it done still is to use the "lower level" surface/surface filleting which can be done between 2 separated surfaces. It can give a fillet surface result in cases where the edge based one gets messed up.

I've attached a model where I constructed a pocket that way - I did a boolean with your piece (I rotated the spheres around so that everything had their seams in one side), then did a boolean to cut, but then to do the fillets I used Edit > Separate on the model to break it into individual surfaces and selected 2 surfaces at a time and then did a Fillet. The surface/surface fillet that was then generated can be used.

To finish it you would need to array the current filleted fragment (which is sunken down into the main object now) around again, then use Edit > Trim to trim the main object by the set of fillet pieces, then join the pieces together. This kind of low level surfacing approach (using surface/surface fillet and trimming) is not as convenient as booelans and edge-based fillets but it can get the job done when the regular filleter is being cranky about something.

- Michael