The failure of fillets is the limiting factor in my design. I'm trying to fillet between two lofted surfaces, and I can only get a .20" fillet when I need at least .80 This happens over and over. How many times have I seen "fillet operation failed, try a face fillet or smaller radius" I have tried face and variable many times, they fail also. I ended up rebuilding the model to make the fillets less complex, but the fillets still have limitations. I have tried creating a section and sweeping it around, that never blends smooth. I am lucky if one of ten fillet attempts work. Quite often I have to give up and rebuild the geometry then try to fillet again. I have spent many more hours fighting with fillets than constructing the geometry.
Does anyone have a better way to complete a model without being at the mercy of the fillet gods. Or a method to make fillets more cooperative.