complex fillets or alternative?

[jamie.q.white]

Some of my designs can't be 3D printed due to sharp creases that cause intractable thermal stresses.  Simply trying to add a fillet to the crease does not work because the fillet command fails.  Is there a good way to add material to the creases so that they are not as sharp?

Thanks!

-jamie

[jamie.q.white]

Oops, forgot.  Here are the relevant files:

BB-lug: http://a360.co/1P06OW6

ST-lug: http://a360.co/1P072fG 

HT-lug: http://a360.co/1P07lY4

[Anonymous]

Have you tried modeling a surface with the curvature you want and using replace face to turn the flat valley of the the slot into a curved fillet?  I've used the approach before with other software on very difficult fillets.

[jamie.q.white]

Thanks for the suggestion.  If I were to do the designs again from scratch, I would sculpt the intersection of the surfaces, which is similar to what I think you're describing. At this point,  I'm trying to avoid re-doing the designs.

-jamie

[Anonymous]

I'm taking a break from most computers for awhile 😉 but looking at your picture I would maybe try splitting the two inward facing faces near the tight corner and doing a loft (in Model or Patch, the latter requiring by Boundary Fill) between these two resulting short faces near the corner.  If needed you could also sketch a guide rail for the loft to get the desired "radius" to the loft.

Jesse

[jamie.q.white]

Hi Jesse,  

Thanks for having a look. I can see how your idea would work.  I tried a loft along the crease, but across the crease is better.  I'll give it a try and see how difficult it turns out to be.

-jamie

[innovatenate]

This may be a good opportunity to test the max fillet script. 

You can check out more about @MichaelAubry's script in the below link.

https://fusion360.autodesk.com/projects/max-fillet-script-tool

Otherwise, you may have to use a variable fillet where the radius is smaller in areas of high curvature. 

I hope this helps. 

Thanks,

[jamie.q.white]

I am still struggling with complex fillets:  3D printed titanium parts cannot have sharp intersections. I spend a lot of time trying to fillet complex curves:

on the lower pipe, I need the fillet to be r = 2mm, but 0.5mm seems to be the maximum.  Sometimes I have some luck filling in the fillet curve with a small pipe and filleting the pipe intersections (upper structure), but this often fails as well.

How does the fillet command generate a fillet? Perhaps if I understood better how the command works, I might have more luck.

Here's a the file I've been working on (downloadable): http://a360.co/1hlHxe1

Thanks!

-jamie

[O.Tan]

Oh wow, you have access to an EOS 3D Printer? Sweet!