Matching a Filet with a Chamfered Edge

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I use Shapr3D to create objects to be printed on a 3D printer. My current challenge is to create an insert for a box which was designed by someone else. The bottom of the box has a chamfer where the bottom meets the sides but is also rounded (has a filet) at the corners. My first version of the model worried first about matching the chamfer, so I wasn’t able to move it into the corner. But the chamfer matched and the side-to-side dimension was good. So I printed a set of filet radius gages and measured the filet. I came up with 20. I applied that to my shape (with the existing chamfer) and re-exported and printed enough to test fit it. But it didn’t fit. I thought it was the gages so I made my own set and printed them and then measured but the two sets of gages match. So why am I getting an under rotated filet (sharper corner) than what I ask it to be? How can I fix this to be the correct radius? Would it work better if I applied the radius and then the chamfer?

–Chip/N1MIE

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Hi Chip, Welcome to the Shapr3D community!
Screenshots would be useful here. :slight_smile: Show us what your work looks like before and after you apply your fillet.

My guess is the fillet stops because it gets to a different face? For this picture I put a little step in the face, and the fillet does not complete a full 90°

IMG_0214
IMG_02141830×1373 404 KB

I think it would be better to do the 20 mm fillets before the little champfers.

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Sorry for the delayed response/update. What I got to work was to go back and undo the chamfer and filet and reverse the order of execution. Then it matched correctly. In some ways it seems odd to me that the order makes a difference and in some ways it makes sense to me. I’m not sure what’s best. But for others I would say that when you have a corner where three planes meet, the order of operation between filet and chamfer will impact the results you get. So if you are trying to match something or achieve a specific look, try both orders and see which matches best or suits your desires best.