topic Re: Solid Fillet Tool giving inconsistant results / wrong result in Fusion Support Forum

Solid Fillet Tool giving inconsistant results / wrong result

TSSmith7 — Sun, 28 Sep 2025 05:34:48 GMT

Hi all,

I'm trying to create pockets in plate-like parts that can be machined with a mill. I have created an add-in that creates pockets in the part that don't have filleted corners from some sketch geometry. The resulting pockets look like:

I want to fillet all the inside corners of the pockets for milling but I get very strange results that are not even reproducible. Here is the result trying to fillet with a 0.3in radius:

Sometimes a selected edge will give an error and if I unselect it then reselect it the error goes away.

I would like to fillet this part with a 0.135in radius which (this time) gave:

with the red circled corner being the only correctly fillet corner. Another time I tried this same model it did two of the corners correctly.....

Model is attached.

Thanks for any help

Re: Solid Fillet Tool giving inconsistant results / wrong result

davebYYPCU — Sun, 28 Sep 2025 09:16:41 GMT

You gotta give Fusion a fighting chance, the internal corners at the rectangle border would never get a cutter in there.

eliminate those with small edit and works as expected.

Might help...

Re: Solid Fillet Tool giving inconsistant results / wrong result

TSSmith7 — Wed, 01 Oct 2025 19:49:56 GMT

Yes thank you I do realize that would solve the issue manually.

I am trying to have this occur automatically with an Add-In. I realize also that this is a somewhat special case for the fillet tool.

This type of geometry occurs very regularly in the Manufacturing Workspace however.

Maybe someone knows if it would be possible to use a 2D Contour operation and then grab the resulting geometry and put that into a sketch? Hopefully without actually switching the user interface to the Manufacturing Workspace and then back to the design workspace.

Thanks again.

Re: Solid Fillet Tool giving inconsistant results / wrong result

TheCADWhisperer — Wed, 01 Oct 2025 20:02:42 GMT

@TSSmith7

With all this symmetry I would have modeled one portion using Thin Feature Extrudes and then Pattern the geometry, but I don't know where you are going with your add-in.

Also, you have a little piece of rubbish in your Sketch1.

Doubt it has anything to do with the issue, but for an add-in I would definitely want clean geometry.

Re: Solid Fillet Tool giving inconsistant results / wrong result

davebYYPCU — Wed, 01 Oct 2025 21:11:47 GMT

@seth.madore did you see this?

Re: Solid Fillet Tool giving inconsistant results / wrong result

seth.madore — Wed, 01 Oct 2025 21:19:02 GMT

@TSSmith7 wrote:

Maybe someone knows if it would be possible to use a 2D Contour operation and then grab the resulting geometry and put that into a sketch? Hopefully without actually switching the user interface to the Manufacturing Workspace and then back to the design workspace.

Technically, one could create toolpaths and use a .dxf post processor to output a file that could be reimported into Fusion. Otherwise, there's not really any other mechanism to do what you're hoping.