topic Re: Error when applying fillet due to the sketch having segments in Fusion Design, Validate & Document Forum

Error when applying fillet due to the sketch having segments

BudSm — Thu, 29 May 2025 21:42:01 GMT

Hello,

I'm pretty new to Fusion, so please forgive my ignorance.

When creating my sketch, I did it in "segments" because it helped my brain work out the correct dimensions and measurements I needed.

But now, after extruding the sketch, I am getting an error when trying to round off the edges with fillets because of these segments. (error: The fillet/chamfer encountered a non-manifold edge or vertex.)

Is there a way to now merge these segments in the sketch into one contiguous shape? (Kind of like merging/flattening layers in photoshop)

Or is there something else I can do to prevent the fillet error?

Re: Error when applying fillet due to the sketch having segments

TheCADWhisperer — Thu, 29 May 2025 22:12:21 GMT

@BudSm

Can you File>Export your *.f3d file to your local drive and then Attach it here to a Reply?

Re: Error when applying fillet due to the sketch having segments

jeff_strater — Thu, 29 May 2025 22:39:13 GMT

Normally, creating a sketch with multiple line segments will not cause a problem, if the lines are colinear. They will be correctly merged into a single edge by the Extrude (I cannot tell if that happened here because the sketch is visible over top of the edges). Your error message is quite specific: It indicates the presence of non-manifold edges in the geometry being filleted. The highlighted edge in this image is an example of an edge with more than two adjacent faces:

I don't see any in your image, but they could be there. As @TheCADWhisperer requested, share your model and we can likely easily find the problem.

Re: Error when applying fillet due to the sketch having segments

BudSm — Thu, 29 May 2025 23:30:00 GMT

Thank you for the replies, I appreciate the help. Here is the .f3d file as requested:

Re: Error when applying fillet due to the sketch having segments

TheCADWhisperer — Thu, 29 May 2025 23:37:51 GMT

@BudSm

Zoom wayyyy in here.

What do you observe?

Are all of your sketches fully defined? (No blue lines.)

Red lock glyph?

Re: Error when applying fillet due to the sketch having segments

BudSm — Thu, 29 May 2025 23:52:04 GMT

Thank you so much, I wish I knew how I managed to do that.

I really appreciate your time.

Re: Error when applying fillet due to the sketch having segments

TheCADWhisperer — Fri, 30 May 2025 00:17:28 GMT

@BudSm wrote:
Thank you so much, I wish I knew how I managed to do that.
I really appreciate your time.

@BudSm

Unconstrained geometry is always building a house of cards on a foundation of quicksand.

Fusion tells you when the geometry is under-constrained in your sketches - you have a lot of this.