VariableFilletSrf

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Variable Fillet Surfaces

The VariableFilletSrf command creates a round tangent surface between edges of intersecting surfaces with varying radius values.

Select two intersecting surfaces for variable fillet on the surfaces near the edge that will be filleted.
Surfaces must intersect.
Handles will appear on surface edges.

Infinite Plane: Type IP for InfinitePlane options.

Press Enter to use the default radii.
Or
Type a new radius distance any time the Radius option displays on the command line.
Specify a command line option.
Or
Select a handle to edit.
Moving a handle at the end of the edge will cause the fillet to extend beyond the surface. This will have to be trimmed by other means.

The Radius and Distance options appear on the command line when you drag a handle grip.

Radius/Distance options
FromCurve	Select a curve. The radius of the curve at the picked location will be used.
FromTwoPoints	Pick two points to show the radius distance.

Handle options
AddHandle	Adds a handle along the edges.
CopyHandle	Adds a new handle using the distance from the selected handle.
RemoveHandle	Visible only when at least one handle has been added.
SetAll	Sets the distance or radius for all handles.
LinkHandles	Editing a single handle updates all handles.

Only added handles can be removed.
The default handles at the ends of each open edge segment cannot be moved or deleted. This is the minimum information the command needs in order to work.
The handle at the end of a single closed edge can be moved but not deleted.

RailType options
DistFromEdge	The distance from the edge curves determines the intersection.
RollingBall	The radius of a rolling ball determines the intersection.
DistBetweenRails	The distance between the edge rails determines the intersection.
TrimAndJoin	Trims and joins the resulting surface to the input surfaces. History only works if TrimAndJoin=No.
Preview	Displays a dynamic preview. You can change the options and the preview will update.

Always fillet from the largest radius to the smallest radius across a model.
Remove any edges you can prior to filleting with MergeAllFaces or by way of surfacing in a simpler manner. Fewer intersected edges = Fewer problems as the fillet rolls along any edges and tries to trim and join with the adjacent surfaces.
Make sure there is enough room for the fillet surface to trim and join with adjacent surfaces. The angle relationships between surfaces, sharpness of the bend in the rail around corners and rail type all play a part in any particular case.

See also