topic Re: Fillet failure for complex curve solid in Fusion Design, Validate & Document Forum

Fillet failure for complex curve solid

klw10x247 — Wed, 05 Nov 2025 05:09:18 GMT

I have been trying to fillet or chamfer the top and bottom edges of this solid but I keep getting the following error.

[The fillet/chamfer could not be created at the requested size.
Try adjusting the size, deselecting some of the edges (try disabling Tangent Chain), or using multiple separate operations.]

0.8mm fillet is the max fillet I can achieve, which I dont find sufficient.

I have also tried a method I found on Youtube on trying to create an off plane surface sketch and cutting my solid via extrusion with tangent but any tangent angle does not work, leaving just and outer edge reduction.

Requesting guidance on the filleting, thank you!

Re: Fillet failure for complex curve solid

laughingcreek — Wed, 05 Nov 2025 03:57:42 GMT

can you export as a .f3d and attach that instead?

Re: Fillet failure for complex curve solid

klw10x247 — Wed, 05 Nov 2025 05:09:40 GMT

Sure, done.

Re: Fillet failure for complex curve solid

TheCADWhisperer — Wed, 05 Nov 2025 06:15:05 GMT

@klw10x247

Where are you getting the dimensions for Sketch1?

This sketch can probably be significantly simplified with zero spline curves.

Toggle Curvature Display.

Add missing dimensions. Do they make logical sense?

Re: Fillet failure for complex curve solid

klw10x247 — Wed, 05 Nov 2025 06:38:56 GMT

it's a trace from an image file. I used the spline curve based on some Youtube tutorial.

How did you draw the above without spline curves? I shall look up a tutorial on this. Would using less spline curves solve the fillet issue?

Re: Fillet failure for complex curve solid

TheCADWhisperer — Wed, 05 Nov 2025 07:00:50 GMT

@klw10x247 wrote:
it's a trace from an image file.

@klw10x247

Do you have the actual part in addition to this image? Do you have calipers to take measurements?

What is the part?

Re: Fillet failure for complex curve solid

klw10x247 — Wed, 05 Nov 2025 07:17:55 GMT

Yes, I have the actual part with calipers. The missing dimension you mentioned is approximately 44.81 - 44.85mm.

Re: Fillet failure for complex curve solid

TheCADWhisperer — Wed, 05 Nov 2025 07:32:29 GMT

@klw10x247

Is the image perfect, or could there be parallax error in the image that makes tracing a bit iffy?

See Attached file.

Edit the dimensions to match your caliper measurements.

I didn't have your 44.85 caliper measurement before I Calibrated the canvas - so my model is a bit larger than true size.

This is the easiest measurement on you model and should have been first dimension in your sketch.

I made the Fillet extra-large to see how high it would go, but I suspect actually around 2mm.

If you have trouble editing the dimensions - post back.

Re: Fillet failure for complex curve solid

klw10x247 — Wed, 05 Nov 2025 09:45:49 GMT

The image was obtained from a scan on a photocopier, please let me know if there's a better option.

The part has fillet/smooth edges too. I am looking into the file now, thank you.

~~Having some troubles editing the center of curves after I have calibrated the Tracing image size.~~ Looks like I can just add a new Arc Tangent, am rebuilding the sketch.

Is there a name for your method of drawing? Tangent constraint?
I'd like to explore resources to learn this drawing technique.

Re: Fillet failure for complex curve solid

TheCADWhisperer — Wed, 05 Nov 2025 17:23:32 GMT

@klw10x247

See Revised part attached.

There is a list of Sketch Constraints.