It turns out the issue was my source 2D outlines from Corel Draw. I'm not sure what the exact issue was. No overlapping points or curly sections. However, I did make some manual edits of control points in Corel.

For the new model below, I started over in Corel and made all outlines by adding and subtraction outlines. No individual point edits were made. Saved as EPS, imported into MoI and extruded and subtracted solids. The nice fillet worked on the first attempt.

I'll see if I have future issues with Corel. If so, I'll need to get up to speed in MoI 2D.

Ed



Test Render in HyperShot