Hello
Why is it impossible to fillet the entire piece correctly on some polysurfaces? Are there always holes left?
Thanks
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post your model please
very few things in Rhino are impossible.
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There is no specific polysurface.
Many of them do not apply the fillet perfectly.
Well there are certain canonical fillet situations Rhino doesn’t know how to handle, but for it to have a chance of working then the model has to be built correctly in the first place and the fillets have to be applied in the correct order–Garbage In, Garbage Out as they say.
With no example there is no help to offer.
That’s why I long ago learned it’s faster to just use FilletSrf as I go instead of all the hassle required to make a model of any complexity properly prepared for perfect p…filletedges.
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There’s threads that try to boil it all down to fundamental reasons, which usually include Rhino not knowing how to automatically extend or retract surface edges that are adjacent to the fillet zone.
This might have something to do with the dev’s philosophy of edges being the main focus of what’s actually a fillet, rather that the faces being what’s filleted. 
I’ve seen product designs evolve where the designer just gives up on even trying to fillet, and the design just adopts sharp edges instead. 
To fillet, or not to fillet.
Does anyone know how to apply fillet (as small as possible) to all edges of this model file?
fillet.3dm (2.0 MB)
Thanks
I have already corrected the mesh and the fillet still doesn’t work
We don’t speak of meshes in this case.
Your object is a polysurface.
It might need reconstruction.
Generally for an object like this it helps to keep step by step inputs and results on separate layers.
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It’s a single piece.
Put it alone in a scene to test it.
The fillet is still impossible
The object in your file is an open polysurface. If the tolerance is set to 0.001 units, the polysurface can be exploded and joined into a closed polysurface.
The small segments on the triangles mentioned make it difficult if not impossible to fillet the edges.
How accurate does the part have to be?
Will it be 3D printed? If yes, you can use Shrinkwrap to first create an inwards offset and then the same amount outwards again. The result will have rounded edges. Depending on your target edge length, you might loose some of the details.
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it’s for architecture.
for very large printing with lots of PPI
Try Shrinkwrap.
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I didn’t understand
What didn’t you understand?
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why use Shrinkwrap
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Ok. So you wrote th object will be 3D printed. This means at some point it will be turned into a mesh no matter what.
You asked for a way to fillet the polysurface. Shrinkwrap inwards and then outwards will result in rounded edges.
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printed on paper in 2D with high resolution
Oh ok. That’s not the printing I expected. Hahahaha
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So you’ll print this with the edges visible or in some kind of rendered look?
You can maybe try edge softening…
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