Fusion 360 Fillet Tool — So Much More Than Just Rounding Edges

Think fillets are just a finishing touch? Think again. In this video, I’ll show you how Fillet can reinforce parts, smooth transitions, and save your 3D prints — all while making your designs look amazing. We'll explore constant, full round, rule fillets, variable fillets, and advanced tricks like chord length and tangent weight — and how to troubleshoot tricky fillet corners. ✅ Constant, Full Round, and Variable Fillets ✅ How to make parts stronger with fillets for 3D printing ✅ Rule Fillets: Instantly round all external or internal edges ✅ Tangent Chain vs. Selecting Edges Manually ✅ Fillet corner types: Default vs. Setback vs. G2 curvature ✅ Chord Length vs. Radius for even edge widths ✅ Tangent Weight: Control how “bulgy” your fillets look ✅ Reinforce stress points in internal corners ✅ Deleting fillets from imported STEP files ✅ Using fillets with splines, edges, and faces — even in box selects 💡 BONUS: I’ve created a Fusion 360 Cheat Sheet Libary! Grab it here: www.resources.techandespresso.com/fillets 🎥Watch Next Brand New User Series With Exercises https://bit.ly/brandnewuser Quick Tips Series https://bit.ly/FusionQuickTips 23 Tips Beginners Should Learn https://bit.ly/Fusion23Tips My Course 🚀 https://bit.ly/Fusion360Jumpstart ⚡Subscribe To Get The Latest Videos https://bit.ly/SubscribeTechEspressoNow 💪🏼Support Me On Patreon https://www.patreon.com/Techandespresso TIME STAMPS FOR FILLET VIDEOS: 00:00 – Intro: Why fillets are more powerful than you think 00:18 – Accessing the Fillet tool (F key or Modify menu) 00:34 – Starting simple: Adding a basic fillet 00:45 – Tip: Fillets can drastically change your model 00:57 – “Constant” fillet setting explained 01:06 – Adding multiple fillets in one feature 01:40 – Editing fillets from the timeline 02:11 – Fillet a face (applies to all surrounding edges) 02:29 – Tangent Chain explained (important gotcha) 02:53 – Selecting tangent edges vs. single edge 03:30 – Select everything and fillet all at once 04:00 – Rule Fillet: Fillet many edges fast 04:13 – Choosing interior vs. exterior fillets 04:45 – 💾 Grab the free cheat sheet 04:51 – Working with imported STEP/SolidWorks files 05:09 – Delete fillets or modify using Q (press/pull) 05:37 – Reinforce parts: Fillets for strength 06:00 – Pro tip: Fillets can add material too! 06:08 – Sketch Fillet vs. 3D Fillet use cases 06:30 – Live preview and editing of 3D fillets 07:10 – CAD best practice: simpler sketches, more features 07:23 – Full Round Fillet: perfect smooth transitions 08:22 – Apply Full Round Fillets to multiple faces 08:47 – Angled faces: uneven fillets explained 09:30 – Fix it with Chord Length (shoutout Matt Perez!) 09:47 – Tangency Weight: Control smoothness of transitions 10:26 – Go beyond 1.0 for exaggerated bulge 10:36 – Corner types: Setback vs. default 11:03 – Variable Fillets: Different radii on the same edge 11:20 – Control start/end radius 12:01 – Add control points for custom fillet profiles 12:09 – Thin middle, thick ends – Variable Fillet example 12:36 – Works on splines and perimeter edges too! ___________________________________________________________________ #Fusion360 #Fusion 360 Tutorial ___________________________________________________________________ DISCLAIMER This video and description may contain affiliate links, which means that if you click on one of the product links, I’ll receive a small commission. This helps you support the channel at no extra cost to you and allows me to continue to make videos like this.