Fillet feature on edges in Solidworks - Step-by-Step Guide

Introduction

The Fillet feature rounds the sharp edges of a 3D model. It helps make designs safer and more visually appealing by smoothing corners.

When you want to remove sharp edges on a product to make it safer to handle

When your design needs smooth transitions between surfaces for better strength

When you want to improve the look of a part by rounding its edges

When preparing a model for manufacturing that requires rounded corners

When you want to reduce stress concentration on edges in mechanical parts

Steps

Step 1: Click

- Features tab

The Features toolbar appears with various modeling tools

Step 2: Select

- Fillet tool in the Features toolbar

The Fillet PropertyManager opens on the left side

Step 3: Click

- Edges of the 3D model in the graphics area

Selected edges highlight and appear in the Fillet selections box

Step 4: Type

- Fillet radius input box in the PropertyManager

The preview updates showing rounded edges with the specified radius

💡 Start with a small radius to see the effect before increasing

Step 5: Click

- OK button in the PropertyManager

The fillet is applied and edges become rounded in the 3D model

Before vs After

Before

3D model shows sharp, angular edges on a rectangular block

After

3D model edges are smoothly rounded with a 5 mm radius fillet

Settings Reference

Fillet radius

📍 Fillet PropertyManager

Controls how much the edge is rounded

Default: 0.01 (default small radius)

Fillet type

📍 Fillet PropertyManager under Options

Defines how the fillet is applied along the edge

Default: Constant size fillet

Edge selection

📍 Graphics area and Fillet selections box

Specifies which edges will be rounded

Default: No edges selected

Common Mistakes

Selecting faces instead of edges for the fillet

The fillet tool on edges only works when edges are selected, not faces

Click directly on the edges you want to fillet, not the flat faces

Using a fillet radius too large for the edge length

A radius larger than the edge length causes errors or no fillet

Choose a radius smaller than the shortest edge length

Summary

Fillet feature rounds sharp edges to improve safety and appearance

Select edges and specify radius to apply the fillet

Ensure radius fits edge length and select edges, not faces