I'm stumped and hoping someone can point me in the right direction:
The attached section is where I have a connector cutout in a plastic enclosure I'm designing. What I'm trying to do is get exactly what I am able to create on the inside edge (VarFillet1) on the outside edge (the inside edge will have no fillet, but using as an example cause it works on this edge).
I suspect the issue is because on the inside edge, that entire face has the same draft angle. However on the outside of the part, the location of the parting line forces me to put opposite draft on the part that will be formed by the B-side of the mold. If I zoom in on the outside face, there are tiny edges between the long horizontal edge and the 1/4 rounds leading in to the short vertical edges and this causes a bit of a hiccup. Even if I did a constant fillet over the whole edge (not what I want) it still has a bit of a hiccup in this area (pictured below).
Any help would be greatly appreciated!