How to fillet a complex extrusion

[Anonymous]

I have an SVG of the outline of the state of Texas.  I extruded it onto a flat cylinder and want to fillet the extrusion.

I selected the face above the XY plane and all of the side faces (there are more than 50 of them). I confirmed that I selected all of the vertical faces as well as the horizontal face.  No matter how small I make the fillet, I am getting an error that

1. the fillet/chamfer could not be created at the requested size. Try adjusting the size, deselecting some of the edges (try disabling tangent chain) or using multiple separate operations.

I tried disabling the tangent chain; no luck.  I tried just a small section; no luck.

I have been working on this for hours with no avail.

Any help would be greatly appreciated.

Thank you!

[g-andresen]

Hi,

that's a recurring problem with such sketches but upload* the file once.

günther

*File > export > save as f3d locally  > attach it to the next post.

[Anonymous]

Thank you, guenther.andresen.  Please see attached.

Best regards

[jeff_strater]

@Anonymous - Fillet is not infallible - it will definitely fail on some geometries.  Areas to look out for:

• high curvature - if an edge has too small of a radius of curvature, Fillet can fail in this area
• "near tangency" - if the edges are close to being tangent, but not precisely tangent, this can confuse the Fillet algorithm.  This is especially true with imported splines, and your entire sketch is made up of imported splines

also, Fillet now will tell you which edges are the ones causing the failure.  Here is what I get when I try a 0.5mm fillet on the top face of this model:

The edges highlighted in red are the ones where the failure occurs

[Anonymous]

Thank you, @jeff_strater for your reply.  Do you have any suggestions on how to accomplish what I looking to do?

Best regards