Design issue

[Anonymous]

Hi all,

I have some troubles designing an enclosure. I have to extrude a small rectangle through a big fillet. But the edges are too sharp and will break easily after being 3D-printed. I need this big fillet to be sure the part won't break. The fillets of the extruded rectangle are maximum authorised by the software. Do you have any idea about how I can make this junction smoother ?

Here is a picture of the actual junction.

[catot]

If you haven't already, try applying all the fillets as the last steps in the model (after the rectangle). Maybe then it can be easier to apply bigger ones?

[TrippyLighting]

I second that advice!

[Anonymous]

I tried to do them all at the latest, but it doesn't change anything. Up to 0.3 mm for the fillet everything looks fine. But I need at least 1.5 mm for the big fillet and it selects automatically the all length of the edge and I still have the same problem. I can't have a fillet of 1.5 mm on the extruded rectangle because it is not large enough (something like 0.6 mm large, 2.5 mm long).

[TrippyLighting]

Could you share you design ?

Export as .f3d and attach to you next post.

[Anonymous]

I think it's because you add all the fillet at the same time, try to add one to the vertical Corner first.

what I am saying is round the corner, the radius of the corner will the decide the max radius of the surrounding fillet.

[Anonymous]

http://autode.sk/25PUtQX

[Anonymous]

I can't share my design, I am working on a confidential project and my boss doesn't want.

I tried to put the biggest fillet in a final position as on the video, but I can do a radius either smaller than 0.5 or bigger than 50 mm. I think I just have too many edges and the fillet is not easy to do...

[PhilProcarioJr]

@Anonymous

Instead of using solid modeling to get that support in the corner use the patch environment to make a smooth flowing piece in the corner then trim your solid with it and add fillets to the ends. Save a copy of your design and cut away everything but that corner area in the copy and post that. Then your boss will be happy and we can give you some real help.

[PhilProcarioJr]

@Anonymous

See if this file helps...it's just quickly thrown together but should show you how to solve your problem.