topic Re: Sheet metal jog fillet in Fusion Support Forum

Sheet metal jog fillet

mpglassbrook — Tue, 30 Sep 2025 12:42:51 GMT

Hello, I'd like to share an issue I was having:

Creating a jog with fillets in sheet metal results in unexpected behaviour.

To replicate.

With flange tool, create a flange from a sketch profile on XY plane.

With flange tool, create a perpendicular flange from edge of initial flange in Z axis.

Extrude cut edge of perpendicular flange from sketch profile on YZ plane.

Using one instance of fillet tool, fillet inside corners then outside corners larger than cut is deep.

Result: Sometimes the cut and fillets are centred to the extruded sketch, but changes asymmetrically when extrude sketch is changed. Sometimes its stable and never changes, Sometimes it's always asymmetric.

Expectation: fillet behaviour should be consistent, left to right.

Re: Sheet metal jog fillet

HughesTooling — Tue, 30 Sep 2025 13:41:27 GMT

I see the same problem but found if I selected the 2 top edges first it seems to reliably create a symmetric shape relative to the sketch. Also seems to maintain symmetry if I change the sketch.

Re: Sheet metal jog fillet

HughesTooling — Tue, 30 Sep 2025 13:55:50 GMT

Experimenting a bit more.

Odd thing is if I select the 2 outer edges first the actual outcome is as if I selected the 2 edges at the bottom of the slot!

Here the fillets on the face nearest were done filleting the outer edges in one fillet feature and the bottom edges in another fillet feature. The fillets on the back surface were done in one fillet feature.

EDIT just to clarify the image above, I created 2 flanges to compare.

Re: Sheet metal jog fillet

mpglassbrook — Tue, 30 Sep 2025 19:12:48 GMT

Interesting, Thank you, your first solution works on my end as well. But annoying that it gives inconsistent results.

You also mentioned something interesting: "as if I selected the 2 edges at the bottom of the slot!" which gave me an aha moment.

When creating a jog with fillets larger than depth, instead of curves intersecting the initial wall at a tangent, they instead coincide with one of the initial edges.
Like this: green is the result if bottom edge gets priority, black is if top gets priority.

Thanks for the insight, I hadn't thought of this.

I feel like if the jog fillet is created in one instance, there should be an option to have the fillets centre, and meet at the wall.

Like this, where purple is current Fusion behaviour and black is desired: