I’ve come across this problem more than a few times and never had a good solution. Sure you can mess around with variable radius fillets, or change the base geometry…. but sometimes that’s just not possible. It just has to work within the given constraints. And you either need rounded edges for manufacturing purposes, or perhaps its safety. Or maybe you just want those beautiful smooth edges that catch the light to make your product stand out in a photoshoot!

At some point this happens:

But it doesn’t have to be… It can be like this, easily:

Check out my Tutorial on YouTube below that shows how to fix this in minutes using the surfacing tools in SolidWorks:

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