To Create Fillets

The Fillet feature command lets you create three types of fillets: edge fillets, face fillets, and full round fillets.

Edge fillets add fillets or rounds to one or more edges of a part. You can create constant-radius and variable-radius fillets, fillets of different sizes, and fillets of different continuity (Tangent or Smooth G2) in a single operation. All fillets and rounds that you create in a single operation become a single feature.

Face fillets are fillets or rounds between two selected face sets, which need not share an edge. A face fillet blends over small edges or other irregular geometry.

Full round fillets are fillets around three adjacent face sets.

Note: If a fillet is applied to a single edge, any operation that deletes the edge results in an error, since the fillet is no longer valid. If a fillet feature is applied to multiple edges, you can delete an edge and the fillet updates to reflect the change, as long as any edge in the set remains. The same behavior is also true when a face is deleted from fillets that were applied to a single face or face set.

Create a Constant-Radius Edge Fillet

1. Click 3D Model tab Modify panel Fillet ,
2. In the Fillet dialog box, select Edge Fillet .
3. 3. In the Constant tab of the Fillet dialog box, enter the radius for the first edge set and select a continuity option:

   • . Applies Tangent (G1) fillets which are tangent to adjacent faces.
   • . Applies Smooth (G2) fillets which are curvature continuous to adjacent faces. Applying this option causes changes in curvature to occur gradually, resulting in smoother, more aesthetically pleasing transitions between faces.
   • . Applies inverted fillets which are curvature continuous to adjacent faces.

     Use the Inverted Fillet option to invert fillets. You can create a fillet with convex edges or concave edges.

     • Convex edges are an external fillet; the fillet is on an outside edge.
     • Concave edges are an internal fillet; the fillet is an edge in between two faces.
     Note: To apply this behavior to models created in earlier versions of Inventor prior to Inventor 2019: Delete and recreate the corner to change an outside fillet to an inside fillet.
4. Choose a Select Mode:
   • Edge. Selects or removes single edges.
   • Loop. Selects or removes the edges of a closed loop on a face.
   • Feature. Selects or removes all edges of a feature that do not result from intersections between the feature and other faces. If used in the assembly environment, only part features can be selected.
5. In the graphics window, select the edges.
6. If necessary, select the participating solids in a multi-body part:
   • All Fillets. Selects or removes all remaining concave edges and corners. This mode requires a separate edge set. Not available in the assembly environment.
   • All Rounds. Selects or removes all remaining convex edges and corners. This mode requires a separate edge set. Not available in the assembly environment.
7. To add fillets with a different radius, add another edge set.
8. (Optional) Click More to specify additional options:
   • Roll Along Sharp Edges. When selected, varies the specified radius when necessary to preserve the edges of adjacent faces:

     When deselected, maintains a constant radius and extend adjacent faces when necessary:

   • Rolling Ball Where Possible. When selected, creates an edge fillet defined as if a ball had been rolled along the edge and around the corners:

     When deselected, creates a continuous tangent transition between edge fillets in sharp corners:

   • Automatic Edge Chain. Sets the edge selection preference for edge fillets. Select to select all tangent edges automatically when selecting an edge to fillet. To select only the indicated edges, clear the check box.
   • Preserve All Features. When selected, checks all features that intersect with the fillet. Their intersections calculate during the fillet operation. When not selected, only the edges that are part of the fillet operation calculate during the operation.
9. (Optional) Specify options in the Setbacks tab:
   • Vertex. Specifies the vertex of the intersecting edges. Select the vertex in the graphics window.
   • Minimal. Allows Autodesk Inventor to define the minimum allowable setback for a given vertex. Often provides the smoothest transition, and increases the success rate of solving difficult vertex fillets.
   • Edge. Specifies one edge of the edges that intersect at the selected vertex. Select an edge in the graphics window.
   • Setback. Specifies the setback distance. Enter the distance.
10. Click OK to finish.

Create a Variable-Radius Edge Fillet

For a variable-radius edge fillet, you set a different radius for the start point and endpoint. You can also add intermediate points, each of which can have a different radius, and specify a transition type, which determines the shape of the fillet.

1. Click 3D Model tab Modify panel Fillet ,
2. In the Fillet dialog box, select Edge Fillet .
3. Click the Variable tab of the Fillet dialog box.
4. In the graphics window, select the edge to fillet.
5. To add points to the edge, move the indicator along the selected edge to the point location, and click to add the point.
   Note: Note: When you add a variable-radius fillet to a closed loop, such as the end of a cylinder, there are no start and endpoints. Add the points at which to define the radii.
6. In the Point list, select the start point and enter its Radius. Repeat for the endpoint.
7. If you added points to the edge, select each one, and enter its Radius and Position.
8. Select a continuity option for each edge:
   • . Applies Tangent (G1) fillets which are tangent to adjacent faces.
   • . Applies Smooth (G2) fillets which are curvature continuous to adjacent faces. Applying this option causes changes in curvature to occur gradually, resulting in smoother, more aesthetically pleasing transitions between faces.
9. To add a fillet to another edge, select Click to Add in the Edges column and repeat steps 4 – 8.
10. Define how variable-radius fillets are created between control points:
    • Smooth Radius Transition. When selected, creates fillets with a gradual blending transition between the points. The transition is tangent (no rate of change between points):Clear the check box to create fillets with linear transitions between the points:
11. (Optional) Click More to specify additional options or Setbacks to create setbacks.
12. Click OK to finish.

Create a Fillet Between Two Faces

1. Click 3D Model tab Modify panel Fillet ,
2. In the Fillet dialog box, select Face Fillet .
3. In the graphics window, select the first face or face set.
4. Select the second face or face set.
   Tip: When selecting more than one face per face set, clear the check box for Optimize for Single Selection. To finish a particular multiple selection, in the context menu, click Continue.
5. When filleting surfaces, click Flip to reverse the side on which to create the fillet for either selection set.
6. Enter a Radius.
7. (Optional) Set the face selection preference.
   • Include Tangent Faces. Select to allow the fillet to continue over tangent, adjacent faces automatically. To create the fillet between only selected faces, clear the check box. This option does not add faces to or remove faces from the selection set.
8. (Optional) Click More to specify additional options:
   • Preserve All Features. When selected, checks all features that intersect with the fillet. Their intersections calculate during the fillet operation. When not selected, only the edges that are part of the fillet operation calculate during the operation.
   • Help Point. In rare conditions, face fillets have multiple solutions. Specifying a help point can help resolve ambiguity, allowing face fillet to provide the appropriate solution. Select to enable help point selection, and then specify a location on a selected face which is nearest to the appropriate fillet. The proximity of the selected point forces the creation of the resulting fillet at the intended location.
9. Click OK.

Show Me How to Create a Fillet Between Faces

Create a Full Round Fillet

1. Click 3D Model tab Modify panel Fillet ,
2. In the Fillet dialog box, select Edge Fillet .
3. In the graphics window, select the face or face set for the first side.
   Tip: When selecting more than one face per face set, clear the check box for Optimize for Single Selection. To finish a particular multiple selection, in the context menu, click Continue.
4. In the graphics window, select the center face or face set.
5. In the graphics window, select the face or face set for the second side.
   Note: The highlight color of the selected faces coordinates with the color swatch on the related selector command.
6. (Optional) Set the face selection preference.
   • Include Tangent Faces. Select to allow the fillet to continue over tangent, adjacent faces automatically. To create the fillet between only selected faces, clear the check box. This option does not add faces to or remove faces from the selection set.
7. (Optional) Click More to specify additional options:
   • Preserve All Features. When selected, checks all features that intersect with the fillet. Their intersections calculate during the fillet operation. When not selected, only the edges that are part of the fillet operation calculate during the operation.
   • Help Point. In rare conditions, face fillets have multiple solutions. Specifying a help point can help resolve ambiguity, allowing face fillet to provide the appropriate solution. Select to enable help point selection, and then specify a location on a selected face which is nearest to the appropriate fillet. The proximity of the selected point forces the creation of the resulting fillet at the intended location.
8. Click OK.

Tips for Using Single or Multiple Fillet Operations

When filleting adjacent edges, you can add the fillets separately or fillet all edges in one operation. Consider the following when deciding whether to use single or multiple operations:

• When adding fillets with the same radius to three adjacent edges, the result is the same whether you add them separately or in one operation. The most efficient method is to add them in one operation.
• If each edge has a different radius, use a single fillet operation, if possible, to ensure a smooth corner. This situation always results in a blended corner.
• When two edges have the same radius and the third edge has a different radius, use a single fillet operation if possible. If you add the fillets as separate operations, the edge with the larger radius must be filleted first.
• When filleting four or more edges, fillet all edges as a single operation.