How to Add Fillet in SolidWorks: Step-by-Step Guide

To add a fillet in SolidWorks, select the Fillet tool from the Features toolbar, then choose the edges or faces you want to round. Set the fillet radius and click OK to apply the smooth curve to your model.

Syntax

The basic steps to add a fillet in SolidWorks are:

• Fillet Tool: Accessed from the Features toolbar or Insert menu.
• Edge/Face Selection: Choose the edges or faces to apply the fillet.
• Radius: Specify the size of the fillet curve.
• Options: Choose fillet type (constant radius, variable radius, face fillet).
• Confirm: Click OK to apply.

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Fillet Tool -> Select Edge(s) -> Set Radius -> Click OK

Example

This example shows how to add a simple constant radius fillet to a cube's edge.

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1. Open your part file with a cube.
2. Click on the <Fillet> tool in the Features toolbar.
3. Select one or more edges of the cube.
4. Enter a fillet radius, e.g., 5 mm.
5. Click <OK> to apply the fillet.
6. The edges will now be rounded with the specified radius.

Output

The selected edges of the cube are rounded with a smooth 5 mm radius curve.

Common Pitfalls

• Trying to fillet edges that are too close or have sharp intersections can cause errors.
• Using a fillet radius larger than the edge length will fail.
• Not selecting edges properly may result in no visible fillet.
• Applying fillets on complex geometry may require adjusting fillet type or using face fillets.

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Wrong: Select edges and set radius larger than edge length -> Fillet fails.
Right: Choose smaller radius within edge limits -> Fillet applies successfully.

Quick Reference

Step	Action	Tip
1	Open part and select Fillet tool	Use Features toolbar or Insert > Features > Fillet/Round
2	Select edges or faces	Hold Ctrl to select multiple edges
3	Set fillet radius	Start with small radius to avoid errors
4	Choose fillet type	Constant radius is simplest; use variable or face fillet for complex shapes
5	Click OK to apply	Preview fillet before confirming

Key Takeaways

Use the Fillet tool from the Features toolbar to add smooth curves to edges.

Always select edges carefully and set a radius that fits the geometry.

Start with a small radius to avoid fillet errors on tight corners.

For complex shapes, consider different fillet types like variable or face fillets.

Preview your fillet before applying to ensure it looks correct.