Hi Joe, can you please post the model so I can take a closer look at it?

Your feeling of potential trouble with the fillet is pretty correct, the more edges running into each other at a point increases the difficulty of the fillet and it can fail to calculate a result in these situations.

In some cases you can get a better result for a complex area by filleting the corners of the initial curves that you are sweeping instead of trying to fillet the results of the sweep.

But joining should work unless the surfaces involved do not touch each other close enough.


For #2 your surfaces are probably fine there, if you post them I will double check them though. What you are seeing there is the display mesh. To display a surface, MoI will break it up into a triangle mesh and what you are seeing here are those triangles. You can increase the display mesh density under Options, but the default density is already fairly high so that is probably not a good idea. But try checking the "add detail to inflections" checkbox - that will boost triangulation in specific areas to help give a smoother result, but that probably won't help out your particular example shown though.

- Michael